The Coleman Experience - A photoblog

11/28/2009 - Side view of floorpan replacement

Sat, 28 Nov 2009 16:05:32 -0800

A good view from the side as the floorpan replacement continues. The driver's side floorpan has now been bolted to the heater channel. Don't forget to seal it good! There are gaskets and sealers available. The next photos I post should show it welded in. :)

Sat, 28 Nov 2009 16:02:54 -0800

Here is a view down the tunnel with both floorpans in place - the one on the right has already been welded, sealed and painted - the one on the left is just sitting in place as I'm making small adjustments to make sure the bolt holes line up.

11/28/2009 - Floorpan job

Sat, 28 Nov 2009 15:59:48 -0800

From underneath the 1974 VW Beetle, you can see the driver's side floorpan that has been welded in already. Today, I'm putting in the passenger-side pan.

11/01/09 - Floorpan welded in and sealed

Sun, 22 Nov 2009 07:50:56 -0800

Once your floorpan is welded in, it's important to seal it to protect it from moisture and road debris. Here, the floorpan has been coated with POR-15 and I'm applied seam-sealer all around the lip. It's also very important to seal the bottom as well. (Hint - wear gloves when working with POR-15. I didn't, and had that stuff on my hands for a week and a half. It does NOT come off.)

10/04/09 - Jim welds VW floorpan

Sun, 22 Nov 2009 07:48:57 -0800

Finally! At long last, I am flying solo, welding my floorpan into the 1974 VW Beetle.

10/04/09 - Prepare to weld

Sun, 22 Nov 2009 07:45:50 -0800

I delayed this project for two years because I was afraid to weld, thinking I would ruin the floorpans. So they sat in the house for two years until I was ready to tackle the job. Welding is not rocket science, but it does pay to do it right and practice a lot with scrap metal. If you have never welded, it helps to find a buddy to help. Here, Scott Hitch works with me, demonstrating the finer points of surface preparation and welding.

10/04/09 - Shaping the VW floorpan

Sun, 22 Nov 2009 07:42:52 -0800

In the last photo I stressed the importance of clean metal-to-metal contact. Another part of that is making sure your floorpan is properly fitted. Don't be afraid to bang on it, because that's what it may take to make sure it is snug and ready to weld.

10/04/09 - Metal to Metal contact

Sun, 22 Nov 2009 07:40:01 -0800

It's critical that you have only clean, metal-to-metal mating surfaces where the floorpan will be welded. What you are seeing in this photo is not correct - I had to remove the pan and grind the paint from the TOP of the floorpan edges as well. The cleaner the bare metal, the better. You don't want paint or other foreign matter to get sucked into your weld.

10/04/09 - Slide the floorpan into the car

Sun, 22 Nov 2009 07:37:10 -0800

The hardest part of doing a body-on VW Beetle floorpan replacement is actually getting the floorpan into place. There is a certain over-under element to it as the pan rests on top of the tunnel lip, but bolts underneath the heater channels. It took some trial and error but with patience and a bit of trimming, it will eventually fit nicely.

10/04/2009 - Prepare the new floorpan

Sun, 22 Nov 2009 07:33:25 -0800

Your new floorpan won't just "fit" in your Volkswagen Beetle - you will have to trim parts of it off and prepare the metal. Here, the floorpan sits awaiting the next step. Notice that the paint has been removed from the metal all the way around.

09/26/09 - Preparing for the new VW floorpan

Sun, 22 Nov 2009 07:30:37 -0800

When replacing your floorpan(s), it is very helpful to have the vehicle on jackstands front and back. This makes it easier to cut and grind and fit.

09/13/09 - Trim the metal before installing floorpan

Sun, 22 Nov 2009 07:27:39 -0800

Use an angle grinder with a cutting wheel to trim the metal after cutting out the floorpan. I left a half-inch lip all the way around.

09/13/09 - New and old floorpans

Sun, 22 Nov 2009 07:19:50 -0800

Here, the old and new passenger-side VW Beetle floorpans lie on the driveway. As you can see, the original floorpan was so rusted that it basically came out in pieces.

09/13/09 - Remove VW floorpan

Sun, 22 Nov 2009 07:16:54 -0800

Cut your old floorpan out with a variety of tools available - my tools of choice were my Sawz-all and a good angle grinder.

09/13/09 - Original Floorpan

Sun, 22 Nov 2009 07:05:22 -0800

This is the floorpan as it originally appeared - there was a basket-ball-sized hole in it - I removed the front seat long ago since the floor was too rusted to support it.