With the age of our favored Mopar project vehicles well past the three decade mark, it's a forgone conclusion that some of the steel will have succumbed to corrosion. In the case of our '70 Duster, the overall condition of the sheetmetal was remarkable, however, there was one troubling area that needed serious attention. Our car was factory equipped with rubber floor mats in place of more common carpeting, and that was the source of the dilemma. Any moisture that seeps beneath the rubber simply becomes encapsulated by it, and, with nowhere to go, it gnaws its way through the metal below. We actually got lucky with our Duster, since three-quarters of the floorpan looked like new, with even the original Hemi Orange paint intact. The driver-side front section, however, was totally shot. It might seem odd that only a small area of the floor would have been eaten by corrosion, but the rubber floor covering explains it. Water could easily have seeped into this area of the floor and would have been confined to just that area.

While we can remember seeing floorpan sections creatively replaced with old street signs, we wanted our Duster put back together just as good as new. Replacement floorpans for a variety of Mopar musclecars are readily available from Year One. These partial floorpans are embossed with the same features as the stockers for a factory look. With the ready availability of sheetmetal, the only major hurdle is installing it. There are numerous techniques for doing this type of repair, but we wanted to avoid any tell-tale signs of a replacement. For this reason, the replacement piece was installed to the factory mounting flanges and butt-welded at the joints to the factory metal. We found the pan from Year One matched the original very well, making the installation trouble free. Replacing a floorpan is a fairly ambitious undertaking, but with the right techniques a real quality job can be the result. Here's a detailed look at how we did it.