Posted on March 31, 2010.
How I replaced the floor pans in a rusty 1962 Chevy II Nova I bought my 1962 Chevy Nova II in 1988 from a friend that I served in the National Guard. The car was pretty good. There was really no problem and I could drive home, in fact, I have no work to the car for a number of years. I drive it to work once or twice a week and still come out on weekends. I was really happy with the car. Three years ago, I decided to repaint it. I know I could take it to a body shop, but I wanted to do myself. I wanted this to be a project of my son and I could work together. I started stripping the car down and it's the beginning of my story.
I figure I'll learn a lot during the process of restoring my Nova back to its original beauty, so I thought I would document the process I will go and put a lot of photos online with the intention of maybe help someone else with their project. So lets' begin!
I deleted everything I can remove the body of the car. I did install an ignition interlock on the firewall so I can start the car and move it, but when the actual painting process begins, I'll be removing the motor and transmission. I started with the floor pans. There was a descent amount of rust on the front and just a little behind. The hump transmission and driveshaft tunnel were very good.
I wanted to buy the entire floor pan and replace it all, but it was more expensive than I wanted and I was not sure if I could manage a job quite as large. I do not know if I had the ability to reduce the whole floor and to replace it without twisting or twisting of the car (it is a convertible). I decided to buy the left and right floor. This covered the front all the way back. After receiving the floor pans, I spent much time thinking and rethinking and strategy on the best way to cut the old and weld in new. Since the entire floor pan was not rusty, I decided to cut only the part rusty and cut what I needed new floor pans replacement and weld in place. I am very pleased with this decision. By simply removing the rusted parts and replace them with new metal, I was able to avoid any torsion or twisting of the car and probably saved me a lot of time.
I was able to reduce the rusted areas in a couple of hours. I used air shears which worked very well. Before purchasing shears, I tried several other methods such as a pneumatic saw, shears and cutting aviation. Believe me when I say that a pair of hydraulic shears at low prices will be a lifesaver. I used the cutting of aviation for the fine cutting and chop it up small adjustment.
Then I separated the front and back of my new floor pans by cutting them in half. I cut the front part of the floor about 2 inches larger than what I needed. I then placed it in front for easy access assay. When I had the replacement pan in place, I have done according to the existing floor pan with a rubber mallet. I used a white spray paint and sprayed on the perimeter of the pot further. When painting around the perimeter, I was able to see where the pot new shape after its removal from the car. I repeated this procedure for the front and then the other two regions of the back. This took me about a day to complete.
The next part needed welding, please be sure to follow all safety rules during welding to avoid any deterioration of living persons!
I was now ready for welding sheet metal replacement in place. That's where my brother was a great help! It has a MIG welder. We inserted the new pots and while I wanted t.