Fixing holes in floor pan and trunk.

[Billdogg]

How should I go about fixing a hole in my floor pan? It's a pretty good size one. Probably 1 square foot from rust to rust. The hole is not actually that big, but from where the surface rust is about that size. I'm guessing that's way too big for a patch. Is there replacement pans available? Or could I get a replacemnet Monte Carlo pan? I'm assuming they're about the same. I'm not concerned about having it look 100% stock.

There's also a small hole, probably 2 square inches in my spare tire compartment. Would this be patchable?

Thanks for any help.

 

[John Larkin]

If the majority of the rust is surface, then just wire brush that really well and vacuum debris out. Find the real hole(s) and see what you have to deal with. Sand the whole area down to bare metal with some aggressive sandpaper (40 grit), and treat it with a rust inhibitor (Must for Rust at Home Depot works ok, Ospho is great if you can find it, use gloves and good ventilation because this is phosphoric acid ). Do this top and bottom. Then find the holes and only cut them beyond the edges of the rust; minimizing metal removal is the key here. Then go to NAPA and get one of their little Fiberglass repair kits, about $9. Lay some duct tape on the bottom of the hole underneath the car and patch the inside first. Then when it sets up hard, do underneath the car also. You can then decide whether to coat it with body filler or just undercoat it. This works good if you follow the kit instructions well (no bubbles in the 'glass, resin mixed properly). You could even sandwich some aluminum from a coke can between the fiberglass; I've done that and it will add some strength. Won't rust either. Sounds like a hack job but you'd be surprised what "professionals" do also.

 

[Billdogg]

Thanks John. That helps me out a lot.

 

[Red Regal T]

If you have a good junkyard near you, you can choose from any G-body car, and cut out the part you need. I see many go to the crusher with perfect floor and trunk pans that look like they are brand new. Just take a couple sharp chisels and a hammer and trim out what you need.

 

[GNX423]

I had a lil bit of drivers floor rot. A few holes from a leak under the dash. I ripped out the carpet, it had to be replaced anyway. and i used the por-15 floor pan restoration kit. First wire brush the floors, use the metal cleaner, than rust inhibitor, it comes with fiber glass cloth that turns rock hard when you use it with the por-15 paint, and epoxy putty to fill in gaps and holes. the final step is 2 coats of por-15 paint. it will take you a weekend, but the floors will never have a problem again.
Good luck,
Mike

 

[Louie L.]

Like above i repaired mine with POR15 and fiberglass cloth and angel hair.I dont know if POR15 fiberglass clothh is any different than the stuff from the body shop but thats what i used. I did about 4 layers and turned out great. But its very important that you seal the holes from the bottom of the car also. Im about to do it again to my T Type.

 

[jsta6]

I did the POR15 and fiberglass also:
http://www.gnttype.org/techarea/bodygauges/floorpans.html