At this point I decided to order some custom molded floor boards from Keyparts Inc. Once the old sheet metal is removed the new floor pans are molded to fit right in and be installed. To install the new parts I began by cutting out as much of the rot as possible, and then grinding and wire brushing any small amounts that was left. Once this was complete I fitted the new floor pans into place, trimming the edges if needed. Once this was completed I then spot welded the floor pan into place. Since the drivers side was so rotten I also and to install a new cross member to mount the seat on, which is the green section in the pictures below. Once I installed both floor pans and had them securely welded in place I purchased Fiberglass resin and mesh cloth and then fiber-glassed over all the edges. I choose to do so for added strength and to also fill any small holes left behind.
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| With joints fiber-glassed |
After I completed the fiberglass and that was completely cured I came in with Herculiner (Truck bed coating) and applied two coats to seal everything up. Once this was completed I also sealed and the joints from the other side with a tube of silicone. I also cleaned the frame rails from surface rust and then sprayed a rubberized coating over the back side of the floor pans and the frame rails.
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| After first coat of Herculiner was installed |
With the rust removed, new metal installed and rust preventative coatings sealing everything up this should be a strong long lasting set of new floor boards.
