Our highest selling product last month was our 1962 - 1966 Dodge/Plymouth complete floor pan kit. Customers usually purchase these kits because their old floor pans on their restoration projects have rotted out or become too rusted. Replacement floor pans can usually be installed at a home garage and are easy to install with the proper equipment and experience. Whether you purchased one of our floor pan kits, or are considering purchasing one, this week we’re going to talk about tips on replacing car’s floor pan.

1.Put the car up on jack stands – This allows you to have easy access underneath the car and provides support to the structure. If the body of the car twists when you’re cutting away at sheet metal, that can spell disaster. Properly supporting the car with jack stands and cutting only of the old panels at a time will help keep the body from twisting.

2.Lay out the old floor pan – This requires patience and a good eye for detail. Lay out the new floor pan on top of the old one. Measure to make sure the new one will fit by comparing it with the old one. There is an old adage when cutting metal that goes: measure twice and cut a little, measure again and cut a little more.

3.Get ready for welding the floor plan in – There are usually to options for welding the new floor pan in. You can use the new floor pan as a template and cut the old pan to the exact fit of the new one and then butt weld it in. The other method is to cut the old floor pan to almost the same size as the new one. You should leave about an inch of extra material around it so that the new pan overlaps the existing floor plan.

4.Seal and prime the new floor pan – When you are done welding the new floor pan in place, you’ll want to apply seam sealer around the restored floor pan. You should also apply a light coating of primer over the seams of the pan for corrosion prevention. Rust and corrosion are one of the top reasons floor pans have to be replaced. One other tip for before you apply the sealer is to closely examine your welds and make sure there are no pinholes or gaps.

5.Make sure you have the proper safety equipment to install the floor pan – Power tools are usually the best option when cutting metal. Because of this, it is very important to wear eye protection to prevent flakes of metal from flying into your eyes. You should also invest in a pair a sturdy leather gloves that will protect you from cutting yourself on metal. If you are doing the welding yourself, it is imperative that you invest in a welder’s apron as well as a mask or goggles. These items protect your eyes from the welding arch as well as prevent your clothes from being burned from sparks.