How to: Repair/Replace Rusty Floor in Vehicle - Complete Guide, Start to Finish
Products Used:
Wire Wheel: amzn.to/3lG8z6V
Corded Drill: amzn.to/3JDQvCs
Spot Weld Drill Bit: amzn.to/3TBy8CT
Bench Vise: amzn.to/42upl9T
4.5” Grinder: amzn.to/3nhGS53
Cutoff tool: amzn.to/42DINRF
Locking c clamp vise grip: amzn.to/3K1R9ej
Aviation Snips: amzn.to/3LMe3b6
Scraper: amzn.to/3JGFhwV
Gasket Scraper Set: amzn.to/40Ey4nU
Ball peen hammer: amzn.to/40evZzA
Chisels: amzn.to/3yZHCy2
Switchable On/Off magnet: amzn.to/3X45sD1
Weld thru coating: amzn.to/40xiw5I
Duplicolor Prep Spray: amzn.to/3K2wEhL
DupliColor Self-Etching Primer: amzn.to/3lku7mH
Dynatron seam sealer: amzn.to/3TBzoG7
welding blanket: amzn.to/42M0lLs
Lincoln 110v Mig Welder: amzn.to/3LKFORe
Auto Darkening Welding Helmet (recommended): amzn.to/3nleH4U
Plasma Cutter : s.vevor.com/bfQa6g
Fluid Film aerosol cans: amzn.to/3e1Sh1X
Floor Pans made in USA (As an eBay Partner, I may be compensated if you make a purchase)
79-83 L+R sides (exact ones I used): ebay.us/3FK9jX
79-83 L Side: ebay.us/hQTch6
79-83 R side: ebay.us/xE5ADP
84-88 L+R sides: ebay.us/rCo1rQ
Floor Pans (made in Thailand):
72-78 L Side w/ mount bracket: ebay.us/B0Gf4A
72-78 R Side w/ mount bracket: ebay.us/BYlatQ
72-78 L Side: ebay.us/lA5WeZ
72-78 R Side: ebay.us/pLky2N
72-78 Full length L+R sides: ebay.us/f69NFj
72-78 Full length L Side: ebay.us/UT8uBI
72-78 Full length R Side: ebay.us/TaQo9I
79-83 L+R sides w/ mount brackets: ebay.us/Oho88U
79-83 L Side w/ mount bracket: ebay.us/AbPsi0
79-83 R side w/ mont bracket: ebay.us/QwW7uJ
84-88 L+R sides w/ mount brackets: ebay.us/PcKCxV
84-88 L Side w/ mount bracket: ebay.us/UqoXYM
84-88 R Side w/ mount bracket: ebay.us/FuEWp2
84-88 Full length L+R sides: ebay.us/hNww5I
84-88 Full length L Side: ebay.us/ax3N1X
84-88 Full length R Side: ebay.us/jSYptl
89-95 L Side: ebay.us/PJqloU
89-95 R Side: ebay.us/1S8RGG
89-95 Full Length L+R Sides: ebay.us/rbumNp
Cutting out the rusty floor in a vehicle and welding in a replacement floor pan or custom cut sheet metal is a long and tedious job. I documented the process from start to finish to offer a complete guide. My vehicle is a very rusty 1980 Toyota pickup, so the rust holes also went up the inside walls of the cab. I used a reproduction floor pan, but also had to fabricate a lot of additional pieces from sheet metal because the floor pans do not cover all of the areas affected by rust.
Rusty 1980 Toyota Pickup Truck Long Bed(s) Build Intro: • My Rusty 1980 Toyota P...
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My used OEM Toyota Parts for sale: yota.6thgeargarage.com/
I don't have Patreon or ask for donations, but you can support the channel with some rad 'Yota gear from my store: 6thgeargarage.com/merchandise/
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I know this is a year old by now, but WOW what a JOB! I can't imagine doing all that work; some people would say it's not worth it but I commend you for tackling it! Very informative and fascinating video. I just recently decided to get into cars so stuff like this is very appreciated! So from one Ohioan to another, thank you!
In my younger days I would have parted this truck out and scrapped the body & frame. I finally decided to take on a true challenge and although it's been a year already, it should be on the road by summer! Thanks for watching!
Here is a tip for easy sound deadening removal. Get a bunch of dry ice, pack it on top of the sound deadening. Once it's cold remove the ice and tap it with a hammer and it will shatter and pop right off.
Beat me to it!
That's if you can get your hands on dry ice. (As in buy it)
@@madcat4563 dry ice is dirt cheap and found in most grocery stores
Warning: if anyone tries this method use proper gloves and avoid touching the dry ice. You can get burns on your hands.
@@lupulflamand5673right.. because the rest of the floor repair can be done without gloves?
The classical music is awesome, a very nice touch. Excellent video
I really like your choice of music. I'm trying to motivate myself to do the floor pans on my Ford Super Duty.
Getting started is honestly the hardest part because it seems overwhelming. Once I got to cutting I was motivated to keep going. Then once you get to the cardboard template phase and see it all starting to come together, you're on the home stretch.
It would have been nice if we had people making replacement floor pans for old cars in my country. Thankfully, we don't have road salt due to know snow, except on mountains. Satisfying video to watch, the time flew by.
you took what seemed like an impossible task and nailed it, mate your a legend and an education thanks
Great channel! Keep up the good work. Following along since I’ve got an 82 4WD short bed that’s undergoing a restoration. Learning a lot from your videos. Thank you
The step drill bit requires a pilot hole. It’s not made to drill its own hole, but to make an existing hole bigger. I think it’s usefully customary to create paper templates before cutting the old out, so you know what you are doing after the old shape is gone.
good idea, thanks!
Hello 6th Gear! I especially like that you took the time to talk about the value of one tool over another, like the aviation snips versus the tin snips for cutting the sheet metal. Sharing your knowledge here is very much appreciated. I am a very amateur sheet metal welder, (MIG), myself and seeing you weld your sheet metal without too, too many "blow-throughs" was encouraging. I have a 40 year old Volvo "Brick" to do some rusty floor repair on, and your video has really inspired me to have at it! And like you indicated, after you clean up the welds, use the seam sealer over the etch-primer in order to seal up any pinholes from moisture creeping in from the other side. And by the way, your bloopers at the end are hilarious. It was great to see your sense of humor. Keep up the GREAT work: your videos are so down-to-earth, informative, and entertaining - all rolled into one! Thank you very much!
Thanks for the comment, I really like to hear that these videos are inspiring/helping others!
I don’t feel so bad about the rust in my 1985 Ram 50! Wow what a mission to repair that! PS a sharp counter sinking drill bit is way more efficient than a step drill. Cool project.
I haven't seen a Ram 50 in ~20 years around here. They all rusted away... awesome little trucks!
Thanks for the video! I'm starting work on my '84 Ramcharger this weekend, and this video was a big help.
Great video, very motivating as always. I have a similar patch to do on the 87 4runner in my snow plow video, it’s by the body mount but only about the size of a fist
if there's a Will there's a Way... Good Job
Thanks, this one was a challenge!
Nice job!! Kiichiro Toyoda would be proud...Found my in the cab leak on my Ca truck. Spot weld rusted through where the water drains from the cowl under the fender, behind the hood hinge box.....would leak just sitting and filled my floor under the vinyl flooring...glad I found the water, was soaked....
Excellent how-to video! Very Informative and I like how organized it is. Videos on auto metalwork by others commonly have long boring moments as they ramble on or try to figure out what to say or do next. Not yours. I was looking for tips as I prepare to patch the floors in my '81 Trans Am. It has very small amounts of rot not nearly as bad as your truck. Very nice music choices too. Liszt, Rosini, Tchaikovsky were nice to hear. Very soothing as I go out to my garage now and try to patch as well as you. Thanks.
Thank you for the feedback! This really helps me figure out what kind of videos I will be making in the future!
Awesome video. Learned a few more tips on how to do these type of sheet metal repaurs. Thank you so much!
As bad as that heap is rusted and you fix all that,you deserve an award, 😂
It's taking a lot longer than expected, but slowly getting There... I like a challenge!
This is great information! Very thorough. Thank you, and the classical music was great! Really enjoyed that part of it.
Done better Job than most professions do they charge 100's hr to do the same, never finish keep milking the customer till they run out money, very nice work. Better you make the patch panels look the better your work will be when finished.
You definitely have given me more confidence for doing this on my 80 4wd once I get the cab done everything else should be “easier”😅
Yeah floors are a lot of work and not much fun... but I'll be happy to know they're solid.
Nicely done, fair amount of work to sort that out. Also if you havent already, id recommend you check out wire wheels for the grinder, used to use them on a drill too but theyre so much faster on a grinder
I do have one on my grinder but I used it to clean some greasy stuff in the past so I didn't want to contaminate the clean bare metal edges.
Nothing but grinder attachments for me. A die grinder with a cut off wheel or a cut off air tool helps get in tight spots. Substitute dremel if no air
Looks great you are a decent welder
Your work is absolutely incredible
Thanks so much! I'm determined to save this truck from the scrap yard
You sir have the patience of Job. That alone is worth the time to watch this video. Your fabrication with basic tools is a great example of what can be done without all the conveniences of a full scale shop. Good job all around and your welding is great. As someone who has done a bit of this type of work myself your fabrication and attention to detail on such a rusty repair is very good. 👍🔨
Thank you very much!
GOOD TO SEE YOUR STILL THROWING OUT NICE VIDEOS THAT ARE VERY EDUCATIONAL 👊🏻👍🏻💪🏻✌️
Thank you! You've been subscribed since the beginning, when I only had a couple thousand subs. I appreciate that!!!
nice video man ! i did that job on many toyota since i first watch your video on the red yota and i become pretty damn good to fab my metal peices with nothing but hammer and a vice !!.. cant wait to see more about that projet
Awesome!! Great job I’m glad I live in South Georgia I don’t have to worry about all that road salt
Great instructional! Now I feel like I could do this.
I did the same thing on my Ford Mustang but didnt ever use welding... I used automotive Floor pan sealer and rivets... Great job !
Thanks! How did that floor pan sealer hold up? That sounds a lot easier than welding.
@@6thGearGarage So far so good ! A lot of the floor pans these days are not even welded but sealed... I used POR-15 undercarriage spray paint over the sealer for that extra added protection. This video was good reference... I do not own a welding machine so this was the best I could do... kzhead.info/sun/jKmBnceIoZR8i4U/bejne.html
Great job man! Greetings from Montenegro 🇲🇪
Thank you!
Excelente trabajo... como de fábrica... te felicito. Saludos desde Argentina.
great video. watched it to prepare to do similar work on my M151 military jeep
Nice jeep, love the old M151's
Great work mate, go easy on yourself with those welds mate they are fine for what you are doing here mate and will last infinately longer than all that rust!
Anyone that knows how to do patchwork correctly will say that you should never just cut everything out all at once that’s rusted. It should be done in sections using the pieces you cut out as templates for your new pieces. cutting out large sections at once without making patterns for new pieces will make it difficult to replace and patch all the metal in a way that it was originally put together. It’s important to take measurements of the pieces you cut out and make card paper templates of all the pieces you remove so when the time comes to reconstruct everything, you don’t have to do any guesswork as to what size or measurements your patch pieces should be. The more you know 🌈⭐️
I understand what you’re saying, but I don’t know if I could work that way by creating templates when the metal all around it is still rusty. I like to remove all the bad and then come up with a game plan from a fresh start and rebuild it in the reverse order. Then again, I am far from a professional. I’m just a guy in my home garage with simple tools. If I ever had a high dollar project, I’d hire someone.
@@6thGearGarage I understand.. i’m just saying it’s a lot less guesswork. If you make panels based off of what you cut out instead of trying to guess that’s all my friend you’re finished product looks good unfortunately a lot of times when you don’t go off of making patterns off the pieces you cut there is an excess of metal introduced, or a deficiency of metal that’s creating pot canning, which is where the model pops in and out the manufacture had a certain amount of metal in mind that was beaded to prevent this type of thing bottom line your product looks good and it was just a suggestion to make things easier..
@@mrgreezy1 Hopefully after some more experience I'll be able to work that way. Seems like it would save a lot of time.
you are offering amazing content! hats off sir.
Thanks!
That's a beatiful work, really amazing.
Thank you very much!
Great video got me inspired. I am going to be doing the same thing to my 85 Chevy. Camaro driver's side floor pan is Pretty bad I was a little afraid to tackle this project myself. But aint not too but to do it rigth also I do have a Lincoln welder 140 mig that i Purchased from home depot so i am ready your video is definitely going to help me out. Great job sir
The biggest help is if you are able to buy preformed floor pans.
@6thGearGarage Thanks For the fast reply. I was able to purchase half of the side that I need I just never done this type of work before But I don't want to pay anyone either. Something I want to try to do myself After watching your video I am confident that I can do it. Also i can tell that you have Weld before because you look like this Is not your first rodeo Anyway, I do appreciate the reply Thanks again.
@@floridamanfishing1390 yes, make sure to be comfortable with your welder and familiar with the settings through practice on scrap metal first.
Back in the day, circa 2005, I used the cover of a computer case to rebuild the floor of my 81 Datsun 720.
Great idea!! Ahhh the good old days when computer cases were still metal.
Brings you back to the eg days huh lol. I swear I feel like I've grown up with you since the forums days lol
I learned a lot on that car
@@6thGearGarage so did I.
70s and 80s car and trucks toyotas are amazing. I have a daihatsu charmant 84 with 3k engine toyota is a super Car. The job with the truck is super,thanks.
I found 1970s pirate treasure in my old mustang after removing the seats and carpet.. lotto tickets.. lighters.. and whole soft packs of cigs
Awesome tips. I'm about to start the restoration of my 1993 Fox Body LX Convertible and I thought it was better to trash it, but you gave me hope. Sorry, but my car is not even close to that truck. I heard people talking Sh!÷ . Now I'm getting my baby back on the road.
Right on… If I can save this rusty turd, then you’ve got this!
Owe my god now my rusty rockers seem like a peace of cake !!!
I did these rockers in another video, at the same time as passenger floor, and it was a lot of work. But if you’re only replacing the outer skin then I agree it’s not too bad.
I will certainly clean up all the surface rust i can reach on the chasis before putting a new floor pan on top of it. That's "once in a lifetime" opportunity to have that part exposed.
Excellent, I would have done the same but this frame is too rotted. I have a better one from a parts truck that I restored to put this cab onto: kzhead.info/sun/mtF_qJqHjKlti6c/bejne.html
Excellent video. Thanks for sharing
Thank you!
Good job!!
Thanks!
Awesome job on the Toyota pick-up
thank you!
Man!! You must love that truck. Even if you finish, what’s it worth? Good luck man be safe.
The 2wd Toyotas aren’t worth nearly as much as the 4wd trucks, so I’m not exactly sure what it would be worth. Plus it’s not an original numbers matching truck, so that really makes me wonder what it would be worth. I’m going to keep it around and use it as a shop truck for hauling parts, lumber and 3wheeler. This has been a challenge to restore, but helped me learn what I’m capable of. 🙂
very good job, well done
Thank you!
I noticed this is old but a heat gun and a good scraper will take care of that sound deadening. Good content and keep grinding.
Good job!
Thanks!
You sir have good taste in music.
感恩了解，謝謝分享！
Nice work! I’ll be doing the same just curious if the type and gage sheet metal you used?
I don’t know the exact thickness, I’d guess 16 gauge? They were old test panels for automotive spray paint.
@@6thGearGarage not 16g maybe 20g
Nice work saving one from the crusher.
Thanks!
Good....JOB....I'm....impressed....👌🏻😎
Thank you!
Лучше использовать резиновый шпатель или кисть(пальцы можно не плохо порезать)
Great job
Thank you!
Pretty Amazing 🎉🎉🎉🎉
Thanks! 😄
Well done
thank you!
At least now the driver dont fall in the road through the rust hole 😂... joke... very well done!
Thank for music!
Very informative video! Please share with me where I can buy these replacement floorpans? Thank you in advance
Thanks! There are links in the description.
What size sheet metal did you use ? Thanks for the video! Really good job!!
These floors were probably about 2mm thick. Some of the scrap metal that I used for fabricating the surrounding area was slightly thinner.
Круто 👍Сейчас восстанавливаю Nissan Terrano wd21 1989😊 полы тоже все сгнили...
Was ur cab sagging down any? I have a 97 F250 where the cab mount is detached from the floor and now the door is pinching with the front fender. Curious how would one would know where to lift the cab exactly to install new floor pan pieces to match with cab mount
This cab was not sagging, but I had a similar problem on my 1985. Here is a short video showing the repair. kzhead.info/sun/aryklNKqqpNsZXk/bejne.html I would lift the cab by the other solid mounting points and support it with the door/fender in place until you can see the gaps are correct. Then repair it in that position. You may want to weld some temporary bracing in place to be sure the cab does not shift at all while you're repairing it. If it's sagging that much, it sounds like you have a lot more rot to cut out and replace than I did.
Have done many floors but have never seen aftermarket floor pans just curious where you found them.
There are a few options on eBay. Links are in the description 👍
งานละเอียด
Lol looks like the cab of my Ford Ranger!
And I thought only a Toyota could rust this much!
I found a cup wire grinder wheel cuts right through Seam sealer effortlessly right to the metal.
I'll try that next time, thanks!
Whats your opinion on bed lining the floor? Would it help with future rust?
I've seen a lot of people do it, but it cold also trap moisture and cause rust if not completely sealed inside and out.
Is weld through primer actually zinc spray? Because I can't buy that primer anywhere in europe
Yes, it does contain some Zinc, but I'm unsure of the other ingredients that make it different from a Zinc spray or Zinc based primer.
Since your floor mount was rusted away gow did you find where the original hight and position for the new one you fabricated? Thanks and continued luck on your project.
I kind of just guessed and set it on top of the body mount bushing to figure out about where it should be.
@@6thGearGarageI would be a little worried about stiffness of the body mount bracket. The original had stiffening darts that your piece didn't. There is a channel called Fitzees Fabrication, he does rust repair with simple tools, check it out. He makes ribs using a hammer and a vise plus stuff he had laying around. Compared to what you started with your repair is good. Thanks for sharing,
@@jimw6991 I have been thinking about that as well. when I pull this cab off of the frame, I'm going to stand it up and take a closer look at that area to see if it can be reinforced.
@6thGearGarage You should be able to add a welded gusset to your bracket on each side of the body mount cushion (doughnut). You want your frame very stiff compared to the body mount to get the isolation out of the system.
Great! Does anyone out there know a good source of replacement panel for a 1984 Toyota BJ75 Landcruiser. Floor pans in particular. Thanks!
Not that I know of, I have not seen any available yet.
Hello, I am from Iraq. I have worked in repairing these cars for years, Toyota Pickup, model 1980
That's interesting that you said the welds on the body mount bracket wasn't your best. Weld through primer is a weld contaminant.
Good point! Also, thanks for defending my subpar welds. I'm a decent welder but some days are better than others :)
Were you using a flux core welder?
No, I used solid .023 wire with gas.
The best part about doing this job is finally completing it and THEN having to do the other side 🤣💀
haha you're not joking... The other side was even more work because I replaced the rocker at the same time: kzhead.info/sun/fdamfseAoqF6jKs/bejne.html
А что в Европе прививки от столбняка не ставят???
Use a paint brush to spread the sealer😊
Good idea, thanks!
At least you got a floor
I believe rocker panel first then floors??
I think either method would work. I started with the floor because it was the most rusty and the rocker panel was pretty good. On the passenger side, I did the rocker panel and floor at the same time: kzhead.info/sun/fdamfseAoqF6jKs/bejne.html
Looking gd .Just getting started on removing rust myself. good to see u can make the bends needed with vise.
Weld primer in between all overlapping seams.... this will start to develop rust in a few days
I spray all cavities with fluid film because it will creep into all tiny spaces and keep an oily film on the metal to prevent rust
I have to do the same job on my truck.
It's a lot of work but it feels good to have it completed.
Would the pickup floor pan fit an 88 4Runner?
Yes it should, they are the same body until after the doors.
@@6thGearGarage okay I will double check to make sure thanks dude
@@6thGearGarage Would the floor pan fit an Extra Cab pickup too? or its only for a regular cab.
@@Random_Car_Guy yes it would, Xtra cab is the same from the seats forward.
@@6thGearGarage Alr thx man I’m 16 and I recently bought a 1988 xtra cab to help me learn how to work on cars I did an oil change and changed the parking brake cable. Now I gotta do the engine belts and floor pans
Where to get suitable metal plate for car model.
Any local metal supply should have what you need.
Thanks @@6thGearGarage
You have to install the rocker panels before you can install the floor pieces
Yep, I replace the passenger rocker panel in another video: kzhead.info/sun/fdamfseAoqF6jKs/bejne.html
nice work........but......if it were me i would have wire brushed the rusty chassis beneath the floor and used reformer & sprayed it before welding in the new floor
I will be pulling this cab off soon to put it on a restored frame. At that point I will take a look at the underside and see if it needs any work.
Dam man I love the tech but those welds need help
The frame corrosion also looks serious.
It's very bad with rust holes in the frame. I got another frame with only light surface rust and painted it: kzhead.info/sun/mtF_qJqHjKlti6c/bejne.html
What mig welder?
I was using a 20 yr old lincoln 110v mig here. I recently got an Arc Captain 110/220 mig and love it... www.arccaptain.com/?ref=mgoljh4u
Use code "6thgeargarage" for additional 5% discount!
Yo my man I recommend you invest it a dremal
I have one but didn't think to use it for this project. I did use it when I had to be very precise when removing the inner fender, and it worked great: kzhead.info/sun/epamktt-eoFpa6s/bejne.html
the frame doesnt look that great either :/ was it worth to fix that car? Great vid nonetheless
You're right, that frame is toast. I had a Parts Truck/frame with only light surface rust shipped from Oklahoma and cleaned/painted it : kzhead.info/sun/mtF_qJqHjKlti6c/bejne.html Once this cab is repaired, it will be moved to the southern frame.
Curious what’s the name/model of that craftsman flat bit chisel scraper!?
It's really old, but I found one on amazon for $28: amzn.to/3ngrQMF or here's a whole set for $23 and they have steel caps on the end: amzn.to/40Ey4nU
I no this video was 5 months ago. I'm just curious how much would a repair like this cost? Even if you can just give me a guesstimation I would really appreciate it
I have no idea, as I've never gotten quotes for anything like this. I'd say at least $1k because of all the time & fabrication.
@@6thGearGarage Thanks for the reply
i would use oportunity, once flooor is out, to clean frame from surface rust, do antirust treatment and paint it.
The frame on this truck was too rusty, but I prepared a different frame in this video, which I will be moving the cab and bed onto: kzhead.info/sun/mtF_qJqHjKlti6c/bejne.html
❤🎉
Should’ve cleaned the chassis when you had a chance
This frame is no good, too much rust from Ohio. I have another frame from the south that I will be putting under this cab: kzhead.info/sun/mtF_qJqHjKlti6c/bejne.html
I am surprised you didn*t cut all the good metal from the parts truck to replace all the rusted parts from the blue pick-up, it would cut cost down it has all the shapes & cont9urs of the pick-up.
I would have but the southern truck's floor was just as bad as the ohio truck's floor.
Taking for ever because ur using the wrong bits.you dont use the 2nd step bit on spot welds.either you use a regular bit or a special bit for spot welds.
Yep, I ended up getting the spot weld drill bit in the video and it works much better.