HOW TO: One piece floor pan install

[jaros44sr]

Originally Posted by jlaird

The floor will be in this weekend. Unfortunately, i am having some problems with the fit of the floor flange at the firewall, particularly at the tranny hump. Theres about a 1/2 gap at the hump. Its too large to hammer. I'm going to have to cut it out and make a new piece. It sucks to have to cut that new floor, but its got to be done. I was thinking about the other people that documented the floor install on this board that didn't have this problem, but there might be a reason for that. msgross has a high hump so he didn't have to match the hump up with the firewall. The other, Tri-Pro, used their new firewall replacement, so again, didn't match up a stock firewall hump to the floor.

Here is the gap:

IIRC,I also had a 1/2" - 3/4" gap, I jacked the hump down in the center, using the bracing as a jack point, with pcs. of 2x4's, and using large C clamps to move it where I wanted it. Start in the center and work the metal into the area you want it. I wouldn't cut it yet, until you have exhausted all other options. I did have a problem in the area you are referring to, but I was able to move it into a workable solution

Here's some pics

[jlaird]

jaros44sr, do you think I should weld the floor in when the cab is resting on its floor or could I do it when the cab is on its back like in my pics, or doesn't it matter?

And WOW, your gap was way worse than mine. I can't believe you closed that up! Nice job. I also can't believe that that gap even existed in the first place being both the floor and the firewall are both new replacements from the same manufacturer.

[jaros44sr]

Originally Posted by jlaird

jaros44sr, do you think I should weld the floor in when the cab is resting on its floor or could I do it when the cab is on its back like in my pics, or doesn't it matter?

And WOW, your gap was way worse than mine. I can't believe you closed that up! Nice job. I also can't believe that that gap even existed in the first place being both the floor and the firewall are both new replacements from the same manufacturer.

Well, that the great thing about metal, you can move it where ever you want. Sometimes it looks really awful until you work with it alittle, then it bends into place. I would still rather work with new metal then try and patch up a rusty floor...Tri-Pro's parts are the best that I've seen, and I've been doing this for quite awhile...

I don't think it really matters which way the cab is laying, you can move it around to get at all the welds

I'll keep watchin'

[jlaird]

Overall, I really like this one-piece floor, I just needed a small amount of tweaking at the firewall flange. For some reason, the last couple of inches of the flange angled down which didn't match my firewall flange which is completely straight across. Instead of forcing it into place(it wouldnt of fit as nice), I made a pie cut and will put a little patch in. No biggie. Here are before and after pics and the area at the firewall it should match up to, then installed and tacked.

before:


after:


installed:


tacked:


here are the areas to be welded cleaned and sprayed with weld thru.


I also put the cab on the floor to insure it was on a solid, flex-free surface.

[jlaird]

and here is the MONEY SHOT!

[rob32472]

I am about to do this install how would you rate this on a scal of one to ten and since i will have to do a pillars and b pillars would it be better to do those first so i would have a way to bolt the cab in for the fit at fire wall. Any tips would be appreciated. BTW this is a great thread love the pics

[jaros44sr]

Originally Posted by jlaird

and here is the MONEY SHOT!

Nice work J, yeah for some reason the flange on the floorboard is like that, I just straitened the flange out and rebent it to fit, but your method looks like it worked as well

Rob, it would be hard to gauge your talents, but I think it is far easier then trying to fit up a bunch of patch panels...either way on your a and b post patches, but having the floor in place may make it easier...jmho

[msgross]

I am doing my pillars last, but I still had part of the A-pillar in place to insure proper alignment. I haven't done any other patches but found that this install was pretty straight forward. You need some welding skill but not that much (i'm proof!).
1. Take a lot of measurements and don't get in a hurry...
2. Have the room to prop your cab on it's back without doing any extra damage..
3. Put in a lot of support to insure that things line up in the end

[msgross]

looks good, I just got home from work and could see the pics, I don't remember my outer edge being hard to fit, one side was gone in the firewall so just made the patch to fit that curve...

[pickup6772]

WoW!!!! Just plain WOW. Please keep us posted, as I'm from NY, too. Does anybody know if anyone make a panel to replace the cowl?? I looked under my dash, and saw stars/swisscheese. With what I don't see for a good replacement cab up here, I might try to fix mine.
Mike

[bama51]

Do you have to remove the cab to do this or is it possible to do it while still sitting on the frame? Sorry, but I'm a newbie at this bodywork stuff, so be gentle with the comments.

[OLDIRON69]

Originally Posted by bama51

Do you have to remove the cab to do this or is it possible to do it while still sitting on the frame? Sorry, but I'm a newbie at this bodywork stuff, so be gentle with the comments.

Yes, if doing the entire floor pan you would need to remove the cab from the frame.

[ebfabman]

Here is one I'm doing for a member here. Its getting a firewall too.

[BlueJeep]

Ooooh, more pics and details of what you're doing to the "scalped" cab, please.

[rob32472]

check out project cod fish to get the details

[msgross]

Originally Posted by ebfabman

Here is one I'm doing for a member here. Its getting a firewall too.

are you doing a video on it? I could have used that... any details on your vent area rebuild?

[rob32472]

We are going to do away with the vents this area will be flat with no boxes keep posted to the project for further details

[3quartertime]

Originally Posted by msgross

are you doing a video on it? I could have used that... any details on your vent area rebuild?

+1... This is a job I'm interested in also. One of the DVD's would be way cool...

[thelonerife]

nice work. a lot of people need to see how this done

[cobrajet21]

This is useful. should be put in FAQ area.

[DD1]

I realize it's been a few years since anyone has commented on this post, however it has inspired me to replace the floor pan in my cab. I am almost finished bracing it, and would appreciate anyone's opinion on whether it is braced enough.

I have done everything except the final door bracing. I want to have the access to the inside before I finish it. I also added some cross beams to attach the lower bracings together.

I'll post an updated pic later, but here is the link to the last page of my thread where you can see the initial bracing pics in the final post.

Thanks!

http://67-72chevytrucks.com/vboard/s...=502964&page=8

[jlaird]

I think you need a cross or diagonal brace someplace (one that goes from driver side to passenger side.) After that, you should be good. There is only so much wiggle room you will have anyway once you get the floor in there.

[DD1]

Originally Posted by jlaird

I think you need a cross or diagonal brace someplace (one that goes from driver side to passenger side.) After that, you should be good. There is only so much wiggle room you will have anyway once you get the floor in there.

Thanks. I will add that to the bracing. I'll post a final pic when I am done. I am bracing it up before I order the floor plan as I don't need to have something that big lying around until I get to it. Pretty motivated at this point though.

I appreciate the feedback and help.

Thanks!

[DD1]

Okay, I think I am done with the braces. Please check out the last post in my thread and let me know what you think. Thanks!

http://67-72chevytrucks.com/vboard/s...=502964&page=8

[mooseknuckles]

glad someone brought this thread back. I'll be going this route as well, my rockers, cab corners, and cab mount area is shot! this seems way easier than piecing it all together the old school way.