91 K5 Inner side panel rust repair

[Big10]

looks great!

 

[83blazertexas]

I would suggest leaving as much of the floor in place as you can while replacing the Cab support in the pic above. You could brace under the outer rocker with a jack and a piece of wood/angle iron whatever to help hold the load when you cut it out. If the rear cab/floor support on that side is shot too (they typically are with that kind of rust) you might want to replace that first to add some more stability. I just went through that too. #Ihaterust It’s a good time to beef up the weak factory floor and bracing while your in there.

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Similar. Just had this wrapped this month!

 

[JamesHenry]

Similar. Just had this wrapped this month!

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Nice work! Hope mine looks that good when I'm done!

 

[ghostfire319]

I messaged AMD recently and they indicated that they have the panels behind the B pillar and in the corner in the works. If everyone will start sending them messages expressing need, it might speed things up a little bit.

So, I was recently in touch with AMD once again and they said that it is planned for the end of 2021 SMH.

 

[ghostfire319]

Thanks. It sounds like your braced up good for what you’re working with. Like Cash said, “one piece at time!” You’ll be happy you took the time to make these repairs when it’s all done.
I think the original design of the floor braces and rockers leads to problems... any water that gets into the front and rear braces drains right into the rockers that are pinch welded all the way across and no where for the water to go. I put a couple of V shaped notches on the inner rockers for some drainage.
On A side note I just got my seat upholstery finished and threw it in this weekend for some motivation to keep going. I am happy how it turned out.

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What did the seats come out of?

 

[Gentleman Jimmy]

What did the seats come out of?

Fronts are from an 02 tahoe (I didn’t want the inside armrests), center console from a ‘13 silverado, rears are from an ‘08 escalade.

 

[ghostfire319]

Fronts are from an 02 tahoe (I didn’t want the inside armrests), center console from a ‘13 silverado, rears are from an ‘08 escalade.

How did you mount them? Cut and weld on the underfloor mounts from the donor vehicles? That is seriously awesome work and they look phenomenal.

 

[Gentleman Jimmy]

How did you mount them? Cut and weld on the underfloor mounts from the donor vehicles? That is seriously awesome work and they look phenomenal.

Thanks! There are lots of ways to do this, this is how I did it... For the rear seats I cut the floor out of the Escalade and grafted it in when I replaced my tail pan and floor. The center console works perfectly with the Tahoe seat bolt pattern. For the front seats (which are much heavier than stock), I beefed up the floor pans to 1/8” in the seating area and added some bracing to tie into the inner rockers. My floor was cracked from just the stock seats (pretty common). I also changed the bolt locations to match the Tahoe bolt pattern and upgraded the hardware to 1/2”. Lastly I added some 1” risers/mounts to the seat brackets to get them to the height I wanted. Hope that makes sense.

 

[ghostfire319]

I am going to have to replace front and rear floors as well. One more question lol, how did you thicken the front floor pans to 1/8"? Double up the stock sheet metal or cut out some 1/8" sheet metal and graft it in?

 

[Gentleman Jimmy]

A little of both, i cut out the cracked areas where the seats were going to mount and made some 1/8” patch panels, then where the new mounting locations are and I added some 16ga squares to the bottom of the panels before I welded the nuts on. You can see the pic of the passenger side from the top on page 2, the 1/2” bolts are in the floor and those are the new bolt locations for those seats.