The Floor Replacement
My trip to St Louis had me bringing a lot of parts home,
including the floor out of a 1965 4 door Falcon. What a lot of
people don't know is the floor pan for a 4 door sedan, 2 door sedan, and 2
door hardtop are the same floor! Because of this, my poor Chicago
car has the ability to have a new floor grafted into it, removing the
holey, rusty remnants of its floor that have been beaten on by Chicago
What did I do?
First off I pressure washed the replacement
floor. This floor came off of a Raleigh, North Carolina car, and was
covered with years of grease and dirt from the road. What was amazing
was after the pressure washing the car never had the thick factory sealer
applied, but sported it factory primer - the floor looked brand new!
I used a spot weld cutter bit along with regular bits to pry
the subframe off of the floor pan. Take your time with this, it can
really wear on you. As it did to me.
The resized floor was ground down to fresh metal on the edges for good welding adhesion. Now its time to get the car ready....
I checked the weather report and drove the car over to the driveway to cut the floor out. Before cutting, realize that you are removing a VERY important structural part of your car. Your car can literally BEND in HALF if you don't brace the car. As soon as you start cutting, keep the doors closed, or build bars that bolt inside the door jams to keep the car straight. I went as far as locking the doors, duct taping around them, AND placed bottle jacks under the rocker boxes to help reinforce. Also mask off any parts of the car that could be damaged by flying sparks: mainly dash, plastic, and GLASS - don't forget to cover ALL glass!
Now cutting can start. If you have a running car,
measure, measure, and measure! Pay attention to where brake lines, gas
lines, and subframe pieces are. My car had an "interesting"
backyard fix to rig the transmission mount. Instead of using/modifying
the stock trans rear cross brace, a previous owner used angle iron and
bolted the trans to it, while anchoring the angle to the subframe with bolts
running through the subframe, and bolted onto the passenger compartment's
After the floor was removed, I used the grinder to clean up
the edges and remainder of the old floor so I have something to weld
to. Then, since the floor pan was too big to fit into the car, I cut
the pan and fit the pieces in separate sections.