Has anyone repaired or replaced the floorboard?

[jonr3]

My floorboard sheet metal is pretty rusty and last night I noticed a couple of cracks around the gas pedal assembly. I thought about trying to weld on some additional sheet metal underneath to strengthen it, but I think it's too far gone.

Now I'm thinking about getting a quarter sheet of 0.125" aluminum diamond plate and making a new floorboard from that. I would need to find a machine shop to roll the edges for me, but I think it would be a pretty easy project.

Any other ideas or suggestions?

[chuckbaynham]

I repaired sections of my Drivers Side with mild steel sheet of same or similar gauge to the original.
It worked good.
Cut out the rusty stuff and piece in new stuff as opposed to patching over or under the rusted section.
Good luck.

[Lochlin]

I did mine too. I used a grinder to get all of the old metal off the frame, welded new stuff on a rhyno-lined it. I put a rubber mat over top of it so I wasn't too worried about the welds and such being perfectly neat and clean. Worked out great.

I thought about using aluminum but I can't weld that and I didn't want to screw into the frame.

[jonr3]

Originally Posted by Lochlin

I did mine too. I used a grinder to get all of the old metal off the frame, welded new stuff on a rhyno-lined it. I put a rubber mat over top of it so I wasn't too worried about the welds and such being perfectly neat and clean. Worked out great.

I thought about using aluminum but I can't weld that and I didn't want to screw into the frame.

Is the stock floorboard welded to the frame? I haven't even looked yet as to how it's mounted...

[Lochlin]

On my 85s the floors are welded on. I would assume the earlier ones are as well but I cant say for sure.

[chuckbaynham]

From the Parts Manual

[jonr3]

Originally Posted by chuckbaynham

From the Parts Manual

Thanks! I keep forgetting to look in my parts manual.

According to that, it looks like it's a 2-piece design and bolts to the frame. That would make it much easier for me to fabricate a new floorboard from aluminum diamond plate. It will still be tough rolling the edges but I think I can do it...

[AKAMick]

Just got through repairing my floor, they are held on my 77 by a number of Phillips head screws and nuts on the floor braces, Oxy Actl torched them to red then they broke free and unscrewed, the bumper has a big bolts through the pans that need removing, torch that to red and it will come free, side grinder with cup brush the scale off pans, then cut patches underside of pans, MIG weld the holes up and cracks, grind the welds to suit, sand blast, Marine epoxy painted them up, bolted back in, undercoated them, underside, topside bed liner paint, good as new, rock solid

[johnny reb]

it bolts together from 2 pieces of metal. 2 bolts on the front bumper 2 bolts midway back 6-8 at the back then a bunch of small bolts i am going to do it on my next build later the problem is all the little bolts that they install the fiberglass ti the floor board with fun ashes to ashes and dust to dust when you work on these carts you play with rust. my friend is a cut off tool.

[AKAMick]

111

Originally Posted by AKAMick

Just got through repairing my floor, they are held on my 77 by a number of Phillips head screws and nuts on the floor braces, Oxy Actl torched them to red then they broke free and unscrewed, the bumper has a big bolts through the pans that need removing, torch that to red and it will come free, side grinder with cup brush the scale off pans, then cut patches underside of pans, MIG weld the holes up and cracks, grind the welds to suit, sand blast, Marine epoxy painted them up, bolted back in, undercoated them, underside, topside bed liner paint, good as new, rock solid