Several items had to be taken care of before I could replace the floor pan itself. First I had to cut out the rusted remains of the original pan. I discovered a hole rusted through the inner wall of the rocker panel so I cut out the section and welded in a patch. As you can see I’m not the best welder on the planet but I got the job done and once the welds were ground down, I couldn’t tell there was a patch there.
In addition to the rocker panel patch I had to repair the rear torque box too. Finally, floor support rail was bent out of shape. I cant imagine what would have damaged it so badly other than a previous owner must have jumped the car and bottomed it out or something similar. Regardless, I used the chassis dimension drawing in the CD version of a shop manual and correctly positioned the replacement floor support and welded it in place.
