Floor pan replacement

[bugedd]

I had an expert on the restoration of British cars look at my shell and tell me a bit about floor pan replacement, as mine should be done. Is there a tutorial, video, or something out there to help walk a rookie thru this processs? I assume the pans from Moss are a good replacement part.

 

[Rut]

I used Moss floor pans and they fit ok, but the pre punched holes don't line up. That said, if both pans need to be replaced like mine I would go with the one piece floor. There will be some fitting required, but it saves you a lot of welding!
Rut

 

[bugedd]

Both pans should be replaced to do things right. Looks like a ton of work

 

[Rut]

It's time consuming, but not difficult work...the biggest pita is drilling out the spot welds. I used the Peter Plouf method of self tapping screws to put everything together and I'm very pleased. Invest in a really good spot weld drill, cutting fluid, slow speed drill, and plenty of beer! An angle grinder is a must have as well.
Rut

 

[bugedd]

Use something like this for the spot welds?
https://www.harborfreight.com/3-8-eighth-inch-double-sided-rotary-spot-weld-cutter-95343.html

 

[Rut]

I bought one of those and it left a cut out that had to be ground off...too much trouble. I picked up 4 5/16" Ti tipped drill bits at Atlas welding today for about $2.25 ea and they really do a good job, much better and cheaper than the ones I get at Lowes or HD. Don't know about local welding shops in your area, but they know their stuff.
Rut

 

[bugedd]

cutting the pans out without some sort of support on the rest of the car would be a bad idea, I'd imagine, as the car could twist?? Maybe do one side at a time?

 

[Rut]

I used a piece of 1" emt conduit flattened on each end, bent and screwed to the upper door hinge and door lock plate for a brace. The car has been on a rotisserie for a couple of years and NONE of the measurements have changed at all. These are **** sturdy cars and as long as the sills are good you shouldn't have a problem.
Rut

 

[Hot Wings]

I bought one of those and it left a cut out that had to be ground off...too much trouble.

If you are planing on resistance spot welding the new panels in place these cutters are about the only option. A good center punch helps to keep them from wandering.

When thru-hole welding is the only practical option I like to use smaller holes than needed to remove the original spot weld with a conventional drill. This lets me match the original spot weld diameter with the MIG. Having a panel without holes also lets me punch/drill the holes in a nice straight line rather than having to follow the original.

No, I'm not OCD. I'm CDO - got to keep the letters alphabetical. :friendly_wink:

 

[Rut]

I like these for a clean cut without leaving a hole. I've drilled out so many spot welds that I barely leave a mark on the inside panel with a good drill bit!
Rut
https://www.ebay.com/itm/3PC-HSCO-T...0916201646&pt=Motors_Automotive_Tools&vxp=mtr

i also like this and wish I had known about it earlier!
https://www.ebay.com/itm/TP-Tools-P...1352091094&pt=Motors_Automotive_Tools&vxp=mtr

 

[Hot Wings]

i also like this and wish I had known about it earlier!
https://www.ebay.com/itm/TP-Tools-P...1352091094&pt=Motors_Automotive_Tools&vxp=mtr

I'd not seen one of these before your post. You must now take full responsibility for my cash flow irregularity layful:.

 

[Rut]

I'm trying to justify it for future projects! I've been pleased with the drill bits I've used, but it just takes so long to do all of them. I'm seriously considering a Harbor Freight 110 volt spot welder for those places it can fit.
Rut

 

[Hot Wings]

I'm seriously considering a Harbor Freight 110 volt spot welder for those places it can fit.
Rut

I've not used the HF welder but it looks identical to the one I bought many years ago. There is a small learning curve and the metal needs to be clean on all the surfaces being welded and well clamped, but the result is fast and neat. With a bit of imagination and some heavy welding cable you can use the power head and make some custom jaws to reach odd spots.