10th TPM&FC Car Show Pics. 2010

Mustang Floor Pan Replacement

Floor pan replacement is not terrible difficult, just rather time consuming.

Do not put car on rotisserie until the floor pans have been replaced.

First you need to remove your interior. This includes all seats, carpet, console and anyting else in the way or that could be damaged. Look for any wiring that may be near as you do not want to damage this. It will be easier if doors and steering column are removed. Also check under car
for fuel lines and brake lines. You will also need to remove emergency brake cables.

Once this is done you can inspect the floor pans for needed repairs. My Mustang needed all 4 footwells replaced and part of the toe boards in front. Even if your seat risers look ok, they should be removed because you will have surface rust under them and this will also make installing the new floor pans easier. The seat risers are spot welded in. Use a spot weld removing drill bit. A chisel will still need to be used after drilling but try not to bend the metal up to much (they will be reinstalled).

Now you know what sheet metal you need to purchase. Do not cut any old rusty sheet metal out untill you have the new stuff!! Take each new floor panel and lay in place. Use as a template to scribe a line around the new metal. This will be your guide as to where to trim your old rusted floor. Do not cut at the line!! Cut leaving enough material to overlap the new sheet metal on top of old for welding (about 1".) Drill small holes around outside edge of new metal for spot welding with a mig welder.

After this is done, put car on rotisserie, turned on it's side and fully weld from bottom side. Skip around to diffrent spots when welding so to much heat buildup does not happen.

This is just one (among many) reasons why a rotisserie is so helpful.

Welding bottom side of floor pans after installing on rotisserie. Can you imagine doing this without a rotisserie laying on your back under the car?