Floorpan Replacement - Glue-In That Floorpan

Auto Body Specialties specializes in "Made in the USA" reproduction floorpans that offer factory fit and appearance. The thicker-than-stock floorpan does need to be trimmed though for that perfect fit.

We trial-fitted the pan several times to make sure it fit, and then carefully trimmed it to overlap the parameter of the opening of the removed floor by an inch all the way around. Eastwood's Nibbler Shear (PN 28191) cut accurately through the thick-gauge sheetmetal.

Next, using a Roper Whitney punch, we punched 1/8-inch holes every 2 or 3 inches around the edges where the new pan overlaps the floor. You can use a drill also. This is for sheetmetal screws used around the parameter of the cut-to-size pan to temporarily hold it in place when glued. With the pan properly positioned over the opening and in place, we also measured and punched the 1/8-inch holes on the inside (center) area that contact the frame and transmission crossmember.

Here's something you may not have, but works really well if you do a lot of metal replacement. It's Eastwood's Hands-Free Panel Holding system (PN 19074). Once the new pan is securely in place, we drilled holes in the frame and the old floor sections for the screws, using the punched holes as a template.

The epoxy-style glue was applied with a special caulk gun along all the contact points of the car's pan and the replacement panel. We recommend you work fast as the glue starts to set-up in 30 minutes. We quickly used sheetmetal screws to suck-in the new pan flush against the stock pan and frame. The adhesive fully cures in about 24 hours.

The next day, a bead of glue was shot around the parameter to help seal it. we used five of the adhesive packs (PN 31087).

We put down some Dynamat Extreme (available from Eastwood) sound and heat insulation. It will help keep the Dart's interior cooler and quieter.

(From left to right) Eastwood's Rust Encapsulator (PN 16060Z black) has been tested to be more effective than well-known brands in UV resistance, rust protection, and durability. Extreme Chassis Black (PN 11175Z satin) is three times more durable than Eastwood's original Chassis Black. The Black Surethane Rubberized Sealer (PN 311152) is a urethane sealer that can help duplicate factory sealed seams on hoods, firewalls, door skins, and floorpans. Gator Guard (PN 10129Z) is a tough pickup truck bedliner coating. It will offer superior adhesion and protection for our new floorpans instead of using undercoating.

On the underside of the car, along the edge of the repair, we used Black Surethane Rubberized Sealer (PN 311152) to protect the frame, rocker, pan, and carpet from water, rust, and dirt. The complete undercarriage will be treated with the Rust Encapsulator. Afterwards, we will cover the underside of the car with Gator Guard (a pickup bedliner) instead of undercoating for better protection from rock chip damage.