Floor Pan Work - Potential Problems

Bullitt

Packin' Heat
Founding Member
Jan 13, 2000
2,743
0
47
Houston, TX
Due to some patchwork problems from past owners (and work I had done previously) I had a full floorpan put in my '67 to make sure it's as sound a foundation as possible.

Took it to a guy that was recommended by another shop. Guy seemed to be extremely knowledgeable, had done a lot of pretty good work (from pictures of cars he had on the wall) and was able to do it in the time I needed.

Picked up the car and was really happy with it from the interior side, but wasn't able to look too much at the underside until I got it home (I know, should have had him jack it up and look at it there......).

Everything seems to be pretty solid from the bottom except a few spots that are troubling to me. These are all on the front driver's side frame rail. It's welded up near as I can tell on the tunnel side to the rail, but the outside has a big gap and doesn't appear to be welded.

FloorPan-DRSide-FrontFrame2.jpg


Floor-Pan-DRSide-FrontFrame.jpg


Then sliding around and looking at the trans crossmember from the engine side, it appears the crossmember isn't welded to the new pan (and he did a shoddy job with the seam sealer).

Floor-Pan-DRSide-Tunnel.jpg


I called him and he states that "that's better than they fit from the factory". This seems like a line to me. Unless someone says otherwise, it doesn't seem real sound to me. I'd like to throw some more weld material at the frame rail and crossmember, but wanted to check with you guys first to see your opinions.

For the record, the passenger side looks perfect! The rest of the work seems to be pretty spot on, so I'm wondering if he just got lazy or maybe that really is how they are (unlikely).
 
The rails should definitely be welded to the floors, otherwise they are hanging there in space. I wouldn't be worried about the sloppiness of the sealer, other than aesthetics, unless of course you suspect it is covering up shoddy (or non-existent) welds.
 
I doubt that guy made even a single weld, all it seems is the rubber holding the pans. All you can do now is to take everything apart and start again, or finish the filling part and hope the rust won't show up after a few winters. One last advise don't buy any of these cars if you like sitting in your appartment more than working on your car
 
IMHO. Oh my god! get a lawyer. This has got to be fixed. Floor pans are a major part of the car structure. This putz should not be working on cars. Just because he has pictures on the wall doesn't mean he built them! Not even close to being acceptible or safe! The sealer is to hide the crap work, and he is to lazy to even do a good job at that.
 
Hard to justify taking it back to the same guy, I'd be worried about him just covering up crappy work again!

I appreciate the input, I was really pissed when I crawled under the car and saw that gap. Certainly never going to leave a shop again without a THOROUGH inspection of it!!
 
Hard to justify taking it back to the same guy, I'd be worried about him just covering up crappy work again!

I appreciate the input, I was really pissed when I crawled under the car and saw that gap. Certainly never going to leave a shop again without a THOROUGH inspection of it!!

Dude in other words: no throughough inspection. Before even thinking about bringing a car, make sure the guy has a welder, a good welder, preferably someone using it at the time of your visit. MIG (ESAB, Lincoln, Miller brands only) no stick electrode (for clarification). If not come other time. If you see someone acrtually welding there then talk about price. If satisfied, bring the car, instruct mechanic to cut the rusted sheet metal and not weld, then come again and see how the car is prepared before actual welding. How sheet metal parts fit to cut openings. Must fit exactly. Gaps more than 1.5-2 mm are too wide, weld will leak and melt the edges. If OK, tell him to spray all internal spaces with some bitumen (IMPORTANT), and instruct him to weld it only, not seal it. Next time have a look at actual welds and if satified tell him to apply seal.