Floor Pan Advice Needed

[RedDirt]

I was thinking of just por-15 the old floor and the new ones and laying them in over the top of the old ones. most of the old pans are cut out already and my new pans are a perfect fit over whats left. I just think it would be stronger this way and once sealed it shouldnt rust. Anyway has anyone done this or should I just cut everything out and lay them in?

 

[Seabronc]

I would at least cut out the remaining rust and then clean the matching edges and use structural epoxy and blind rivets. I'm not a particular lover of welds as that is where rust starts due to galvanic action, plus if you don't weld sheet metal properly it will warp. Some might argue with me but more body shops are using structural epoxy especially on body panels and I have never had a problem with this method. I use FUSOR 208B for smaller areas that can be assembled fairly quickly, and 112B for areas that need more working time, available through the net or professional body parts suppliers. Before assembling I clean the surface to the bare sheet metal and then use a product called Piklex 20 to **** any microscopic rust, also available via the net, you just brush it on the area, wait a few minutes and then rub off the excess. Also predrill all blind rivet holes and then remove the burs prior to attaching.

Good luck no matter which way you decide to go

A couple of pictures attached , The clamps shown were removed after 4 blnd rivets were in place to hold the panel in position..

 

[Rons beast]

Never used epoxy for that kind of repair, but it sounds like it's the answer. I will try that the next time I need to replace a pannel.

I know the trick on either method is to make sure the edges are sealed well. Use a good undercoating/ sealer on the underside, and I have found that inside the cab the floors and pannels can be sealed and made quieter and cooler with a product for roofs called Storm Guard. It's like Dynamat but a lot less expensive per square foot because you buy it in big rolls. Find it at the Depot or Lowes. It isn't quite as thick but it will make a floor waterproof if covered correctly. No water...less rust likely.

Good Luck