Blue line K5
Newbie
Hello everyone. I am new here and see that there is quite a bit of wonderful knowledge. Could someone please point me to a thread regarding replacing the floor and rocker boxes? Thank you very much.
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Floor replacement
- Thread starter Blue line K5
- Start date
I don't know of any threads, you may be able to look at build threads in the driveway section.
I am thinking that it will be a process of bracing the body to maintain the door opening and then slowly cut spot welds to remove the metal you need to replace. I personally don't remove any factory metal that I can clean enough and still be good. What I am saying, is don't remove the whole floor if you only need to replace 1/2 of it. I have seen some guys think that they have to use the complete replacement panel.
I would spend some time looking at Greg's build.
@Greg72 can you point him to your thread?
I am thinking that it will be a process of bracing the body to maintain the door opening and then slowly cut spot welds to remove the metal you need to replace. I personally don't remove any factory metal that I can clean enough and still be good. What I am saying, is don't remove the whole floor if you only need to replace 1/2 of it. I have seen some guys think that they have to use the complete replacement panel.
I would spend some time looking at Greg's build.
@Greg72 can you point him to your thread?
Blue line K5
Newbie
Thanks for the advice. I’ll make sure to only replace what is needed.
I have some pictures in my build thread... just click the number to the right of Build(s) at the bottom of my avatar section.
Blue line K5
Newbie
Great! Thanks for the help.
If you sort the threads in that build area by number of views, it’s always easy to find!
https://ck5.com/forums/ck5/the-driveway-build-threads.91/?order=view_count
Quick synopsis:
1. There is always more rust hiding in there than you think. ALWAYS.
2. To replace the floor you start by removing the outer rocker, then the inner rocker, then the torsion box underneath
3. There are a number of sheet metal panels that all converge in the lower A-pillar area (what I call the “2-bolts area”) so if you want to remover rust effectively, you need to work your way all the way in....and then replace with fresh metal and work your way back out.
4. BRACE THE DOORS! BRACE THE DOORS! BRACE THE DOORS! If you remove all the affected metal the firewall and A-pillar will be swinging in the breeze and you will lose all door gap reference points, and your door probably won’t fit right when you try to reinstall it.
....ok, not a quick synopsis, but the actual process is much more involved than what I described here. My build starts out dealing with this issue so if you start at the beginning you will quickly find what you want to know...
-G
Blue line K5
Newbie
Greg, thanks for the great information. I plan on getting my hands dirty on this in the next couple of weeks. Happy New Year!If you sort the threads in that build area by number of views, it’s always easy to find!
https://ck5.com/forums/ck5/the-driveway-build-threads.91/?order=view_count
Quick synopsis:
1. There is always more rust hiding in there than you think. ALWAYS.
2. To replace the floor you start by removing the outer rocker, then the inner rocker, then the torsion box underneath
3. There are a number of sheet metal panels that all converge in the lower A-pillar area (what I call the “2-bolts area”) so if you want to remover rust effectively, you need to work your way all the way in....and then replace with fresh metal and work your way back out.
4. BRACE THE DOORS! BRACE THE DOORS! BRACE THE DOORS! If you remove all the affected metal the firewall and A-pillar will be swinging in the breeze and you will lose all door gap reference points, and your door probably won’t fit right when you try to reinstall it.
....ok, not a quick synopsis, but the actual process is much more involved than what I described here. My build starts out dealing with this issue so if you start at the beginning you will quickly find what you want to know...
-G
Here are a few pictures of how ugly it can get. Once you remove the rusted pieces is starts to look better. Save all removed pieces for future reference. If you haven't removed the fiberglass top
yet I suggest you wait until all floor, rocker box, etc. repairs are complete. There are at least 13 separate patch panels or pieces on each side including the rocker box and outer rocker panel.
yet I suggest you wait until all floor, rocker box, etc. repairs are complete. There are at least 13 separate patch panels or pieces on each side including the rocker box and outer rocker panel.
Here are the parts ready for installing. Left to right, door hinge net plate, nut plate retainer(home made), floor reinforcement plate(home made), front edge for cab floor, rear cab floor support, read pillar patch, kick
panel patch, cab support, front floor section, inner rocker panel, rocker box reinforcement w/ b-pillar patch attached, and rocker box end cap. Not pictured, front fender reinforcement plate, rocker box, outer
rocker panel.
In the second photo you can understand the importance of bracing the doors. Not much left holding the front of the cab.
panel patch, cab support, front floor section, inner rocker panel, rocker box reinforcement w/ b-pillar patch attached, and rocker box end cap. Not pictured, front fender reinforcement plate, rocker box, outer
rocker panel.
In the second photo you can understand the importance of bracing the doors. Not much left holding the front of the cab.
Finished welding driver side. This was my first attempt welding sheet metal/body work. I'll just say my floor now has a lot of character. Clean up passenger side for final fit and weld.
