Kyle,
 
The rule I use is to cut out as little metal as possible. In other words, I just cut out the rust and cut a piece out of the patch panel to fill the hole. The patch should be as exact as you can make it with no overlap so that you can make a butt weld with your mig welder. That way when you grind down the weld its difficult to tell that anything has been changed from stock.
 
Larry
-----Original Message-----
From: [EMAIL PROTECTED] [mailto:[EMAIL PROTECTED]On Behalf Of Kyle Bennett
Sent: Monday, November 03, 2003 2:06 PM
To: [EMAIL PROTECTED]
Subject: [Chevelle-list] replacing floorpans

I just started replacing my floor pans today. I've got a question for you sheet metal people.
 
Where i started removing the floor pan against the rocker panel, i ran into a question. It looks like there is 3 layers of metal in this area. I know this car has never had the pans replaced so no extra metal has been covered up.
 
I have attached a picture of this to better explain, so we'll see if it shows up on this server..if not i'll link a picture. In the picture you can see the rocker panel is the top layer, the remaining floor pan is the second layer and the body metal is the bottom (third layer).
 
Question: Do you have to completely remove the floor pan (middle layer) before installing the new floor, or do you just cut out what you can, then bend the rocker panel metal (top layer) over top and weld into place. If you don't do it that way, it looks as if you need to remove the entire rocker to grind out all of the old floor pan.
 
Help me out here if you would.
 
Thanks,
Kyle Bennett
http://home.nc.rr.com/turbo240sx/DSC00202.JPG
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