Pan replacement on a Duetto

[akitaman]

That was nice of you to say. But, I must admit I didn't put very much effort in it.

[red69]

I thought I would revive this thread, as I need some help that hopefully others can benefit from also.

I am replacing all four floor pans, which are rusted quite badly in the usual places, but the edges and inner sills are in good condition.

I have purchased the european pans and they are high quality.

Here is the question:

Should I:

1. When I remove the old floor, should I leave a flange of the old panel along the perimeter of the inner sill and transmission tunnel and trim the new panels appropriately and (butt) weld them to this flange.

OR

2. Remove the old pans completely by removing the original spot welds to the tunnel and inner sill. If I go this route, how do you fit the new floors? It seems like they need to go in above the central channel, but below the inner sill. I don't really want to cut them in half, which seems to be one solution.

Thanks for your input. Those floors are expensive, and I don't want to screw this up!

Marc

[Stan Murray]

To do them originally you just slip the door side in first and then lower it to the tunnel.
A little pounding with your fist or a rubber hammer and you're in. Trim a notch off the downward lip for the cross member. You have to plug weld (mig spot weld) the lip from below, as well as above on the braces. Jack the car up really high and support it well and evenly. I welded a brace in the doorway while I did each side. One at a time.

Or weld from the top by trimming down the lip and leaving enough of the old floor to plug weld and butt weld, if the metal is good enough. Cleaning the old metal up and then priming with welding primer. Then use seam sealer top and bottom to protect after welding.