Where to cut the floor
 

Ok, I am now onto the pass rear floor pan! Question, where should I cut the original floor back to? I can either butt weld the new pan to the old floor just in front of the rear body brace. Or, should I cut it back so that the new pan will sit on the front lip of the brace?

Re: Where to cut the floor
 

https://www.fordbarn.com/forum/attac...p;d=1771819769

Where to cut the floor ?

Re: Where to cut the floor
 

I prefer putting the new on top of the body brace. I drill out the spots, cut the old in the middle of the spots, spot the new at the old spots then finish all the wat around matting the new and old. From under it looks like new pans were never put in.....just my thing. Either way will work well.

Re: Where to cut the floor
 

A lot depends on the way the corroded area was originally formed. The low spots where moisture can congregate are the worst of it. The old carpet and pad didn't help with moisture much either. I always hope that I can use structural grooves or other formed areas that may prevent warpage during welding. I still use gas welding for that type of stuff since I have aircraft type torches. I butt weld so I try to get the fit as close as possible to avoid use of filler rod. I tack everything in before final welding. I've learned how long a weld I can make before stopping for area cooling and moving to a different location for the same. Close joints give excellent penetration as well. I don't get too worried about what the underside looks like but it generally looks fine after I get done. A little sanding will level most stuff out but if you can't see it, don't worry about it. I only spot weld panels if they were originally spot welded to an underneath structure. They are more of a plug weld than a spot weld but they look the same when I'm done.

Re: Where to cut the floor
 

I do the same. Like to hide the seam over a brace/body mount so you can't see it from underneath.