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Old 09-11-2006, 05:36 PM
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Pan replacement on a Duetto

I was asked to post the process of replacing the floor pans on a Duetto that I'm working on. It's always my intent to repeat the way the factory did it. That means spot weld when needed (if possible). The one thing I always try to do when the chance is given, is I try to improve the cars rust prevention. after all the pans wouldn't need replacement if there was room for improvement.

Here's our beautiful Duetto we have to work with. Charlie has his job cut out for him today....


Once Charlie and Eric got the seats out, we had a good idea of what we were working with. We started with the passenger side because it's easier, and i believe it's important to establish a rhythm when doing this type of work.



When cutting the floor out cover everything. The tar sound deadening product goes everywhere. The sparks can instantly ruin a cloth convertible top.


Charlie is cutting this side out in sections. The frame rail is there, the fuel supply and return line are in the area.


As you can see the fuel lines are close! Be careful. If you don't own tools that use minimal surface to cut, then disconnect the lines before you start. The small circles on the rail are from a special spot welding drill bit.


We will continue this in the morning.
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Old 09-11-2006, 09:18 PM
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red69 red69 is offline
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Following this one closely...

Akitaman,

I really appreciate you taking the time and effort from an obviously busy schedule to post this.

Marc
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Old 09-11-2006, 09:39 PM
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no problem my friend!
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1967 GT sprint Veloce
1969 GTV
1967 Giulia Super
1967 Duetto
1972 Spider
1959 Lancia Flaminia GT
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Old 09-12-2006, 11:47 AM
Stan Murray Stan Murray is offline
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Which type pans are you using..Wolf Steel or original ReMfg?
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Old 09-12-2006, 12:11 PM
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great thread...was thinking of doing this myself

are you going to spot weld everything...did you consider the new epoxy instead for any of the work instead of welding? (other areas)
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Old 09-12-2006, 05:17 PM
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Hi Stan, In this case I used floor pans I ordered from England. At times they have sent me NOS floors. But when they don't, the original style unit they do send are excellent. Nothing wrong wolf steel, I use there stuff all the time. It's just a matter of what is convenient for me at the time.

Hi Alfaman, Floors aren't all that difficult to do, just think carefully before you cut, how you plan on installing the pans. It's very easy to over cut the metal and you'll have a gap to deal with. As for epoxy.... I have no ill thoughts on the subject, I just wouldn't use it in a area that is structural (like the floor) on a 40 year old car. Metal is predictable on how it will act in a accident. I don't know how it will act if it's epoxied. I have comfort in the strength of a weld in these cases. ICAR is a national group that body shops are in effect measured by. ICAR has tons of data on all sorts of products, to include epoxies. A great deal of cars are built or rebuilt using special epoxies. But this is following the cars manufacture guide line. This is how cars are tested and designed. But cars were not built 40 years ago using this stuff. So it would be unpredictable as to how a car would hold up using it.... just my thoughts.

Okay, Charlie did some good work on this today. He was very careful as to preserve the seam inside the tire well. Why? well this is an area that a collector will look to see if the car was compromised.


Once the pan was out, he injected cavity wax in the frame rail. Simply because there would be no better time to. No, the car was never injected from the factory, but we want it on the road for many more years, so why not do the little things to spare it from rust.


Once you trim the replacement pan, it should sit on the center rail flash as you can see here.


Now it's time to start welding. We punched out where we plan to weld about every 3/4 of an inch. Why? Well the factory spot welded about the same gap. And we want predictability (in case of an accident). The center rail was spaced wider because we used a larger plug weld.


we won't be getting back on this car until Thursday. So I'll update it then.

thanks for looking!
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1967 GT sprint Veloce
1969 GTV
1967 Giulia Super
1967 Duetto
1972 Spider
1959 Lancia Flaminia GT
1 very understanding wife!

http://www.vintagecustoms.net
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Old 09-13-2006, 12:12 AM
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Excellent! I'll be doing the same eventually...
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Old 09-13-2006, 08:28 AM
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Don't forget we want pictures Sean!
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1967 GT sprint Veloce
1969 GTV
1967 Giulia Super
1967 Duetto
1972 Spider
1959 Lancia Flaminia GT
1 very understanding wife!

http://www.vintagecustoms.net
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Old 09-13-2006, 08:48 AM
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thanks for your opinion....i will be trying your dash restoration this wkend...
by the way
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Old 09-14-2006, 07:34 PM
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Now that charlie was focused on the driver side. You can see why I wanted him to do it last. The exhaust, clutch and brake lines are in the way and you need to be patient with it. Again he cuts it out in sections. This reduces the risk of over cutting and cutting something else.



As in many of these cars, this too had bogus floor repairs. This was cheap, thin galvanized sheet metal that was riveted in.


The point of this photo was to point out that when Charlie started unbolting things he used zip ties to hold the products. We don't want to stress the hydraulic lines.


At this point Charlie was trimming and fitting the pan in place. He'll welded it in tomorrow. We have to seal, undercoat, sound deaden and put the interior back in for a Monday delivery.


And yes, when we move into the shop, a lift is on the short list.
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1967 GT sprint Veloce
1969 GTV
1967 Giulia Super
1967 Duetto
1972 Spider
1959 Lancia Flaminia GT
1 very understanding wife!

http://www.vintagecustoms.net
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Old 09-14-2006, 07:41 PM
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Quote:
Originally Posted by akitaman
Don't forget we want pictures Sean!
You betcha!

Quote:
Originally Posted by akitaman
At this point Charlie was trimming and fitting the pan in place. He'll welded it in tomorrow. We have to seal, undercoat, sound deaden and put the interior back in for a Monday delivery.
You don't need no stinking sound deadening! My dad took it off the floor panels of his GTV and it made it a lot lighter.
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Old 09-14-2006, 07:46 PM
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Whats That....... I Can't Here You!!!
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1969 GTV
1967 Giulia Super
1967 Duetto
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Old 09-14-2006, 07:50 PM
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...say again?
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Old 09-18-2006, 08:27 PM
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I'm sorry I haven't maintained this thread as well as I could. This job needed to be finished while I had to travel south to pick up a car in California. Charlie welded in the driver side pan on Friday. That left the undercoating and seam sealing to be next.

What I wanted to point out on this picture is, notice how tight the pan is against frame. When welding your pans in make sure you get it that tight. This will improve your chance against rust and the weld to not break. When seam sealed then undercoated.



In this picture note how we kept the front seam in place..... just like factory!


We used truck bed liner on the top too. Great noise reduction product.



And here we are taking it back to Seattle.



Again sorry for not doing a better documentation. We'll do better next time.
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1967 GT sprint Veloce
1969 GTV
1967 Giulia Super
1967 Duetto
1972 Spider
1959 Lancia Flaminia GT
1 very understanding wife!

http://www.vintagecustoms.net
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Old 09-19-2006, 06:56 PM
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This was a great thread. I'm in store for pan replacement at some date, so it was very informative. Nice job, by the way. Looking forward to future installments (no pun intended). Thanks
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