Tag Archives: rusty

  • Removing Rusty Floor Pans (Hands On Cars E.03)

    Episode Summary:

    Using a rotisserie, an Eastwood MIG 175 welder, replacement stampings from National Part Depot and a BFH Kevin gets to work replacing the floorpans on the Zed Sled 1978 Chevy Camaro. After stripping the body shell inside and out, it’s apparent the floors are in much worse shape than initially thought. Luckily the under braces are still structurally sound, and the GM F-body has great aftermarket support, so replacement sheet metal is available. The toe boards, the area right under the dashboard, are not available but are relatively simple to make flat metal pieces. The next step is drilling out the spot welds on the braces, and marking and cutting the old floor out. Then the new one is laid so the location of the braces and edges can be marked with a sharpie.

    Back in the shop Kevin fits the car to the floorpans using the angle grinder, cut off wheel and a big freakin’ hammer. Next he copies the location of the original factory welds all the way around, and drills about a million holes. After a little more cutting and banging and drilling, the new pan is ready to go in. A handful of sheetmetal screws hold it in place temporarily, and a million little holes get MIG welded through to what’s left of the old floor.

    How to Remove & Replace Floor Pans: A Step-by-Step

    In this episode of Hands on Cars Kevin shows us how to remove the rusty old floor pans on the 1978 Chevy Camaro Z28 Zed Sled project car and fit new replacement metal. After stripping the car down to the bone, it become apparent things are worse than expected.

    step 1


    1: New floorboards were needed from National Parts Depot, as well as some custom fab work to replace the rusted out toe boards directly under where your feet go.

    step 2

     

    step 2-2

     

    2. When stripping the car, be sure to save things like rusty old brake and fuel lines to use as a template later for the new ones.

    step 3

     

    3: Eastwood PRE painting prep cleaner is used to wipe off all the protective rustproof coating on the new floorpan so it can be written on with a Sharpie and welded.

    step 4

     

    4: Lay the new metal on top of the old and it should be an exact match. Trace around the edges of new piece on the old floor and you instantly have a guide for cutting.

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    5: Cut out the old floor - There are several different ways to take out old floor pans and it depends on your budget and the car. If you have a plasma cutter you can make short work out of cutting out the old floor, if not a cut off wheel in an angle grinder, and maybe a Sawzall will do the same job, it will just take longer. Leave an inch or so of old metal all the way around to weld the new floor to.

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    6: Be extra careful to cut around the structural floor braces, you are going to want to reuse them if they are in good shape.

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    7: Once most of the floor is out, drill the spot welds holding the braces to what’s left of the floor with an Eastwood Spot Weld Cutter. When the spot welds are out finish the removal with an air chisel in just seconds, or manually with the big freakin’ hammer and an old chisel.

    step 8

     

    8: Use a handful of sheet metal screws and securely attach the new floor to the old edges.

    Screen shot 2014-10-29 at 2.16.33 PM

     

    9: Working from the underside, trace the edges of the old floor on the new one so you can more easily locate all the holes for the welds.

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    10: Take the new floor back out, and mark the location to drill for your eleventy billion plug weld holes. The structure of the unibody relies on the approximately 7000 plug welds GM used in the factory to tie it all together. Drilling holes in the new floor, and welding through to the old from the top helps pull it all together as you weld, for a more solid and water tight job.

    step 10

     

    11: Start drilling holes around the outside edges of the new floor, and the inner areas where it connects to the cross braces. Try to get as many welds as the factory used, and in the same locations for maximum structural rigidity. Make sure you have a good sharp bit before you start, in fact make sure you have a several spares as well.

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    12: Next finish prepping the edges of the old floor and the braces to be welded to. Eastwood Rust Encapsulater is a great preemptive measure to spray on the cross braces and any areas that you won’t be able to get at later when the floor is in.

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    13: The areas to be welded to should have been masked off first, those will be coated with an Eastwood self-etching weld through zinc primer which is made for situations exactly like this.

    step 12

     

    14: Temporarily attach the floor again with sheet metal screws, then start welding. The actual number of holes and welds is more like 300 vs than 7,000, but it still feels like a heck of a lot.

    step 14

    That's It

    And that’s it, your project car has new floors, once you finish all those little welds. There is still the matter of the toe boards, but that is a job for another day.

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  • How to Replace A Rusty Lower Door Skin

    When looking over Project Pile House we started seeing a lot of spots where we needed to repair rusted panels on the body. When sizing it all up, we found that many of them could be replaced with the combination of some basic hand tools and our new Patch Panel Install Kit. We decided to show you an outline of how to tackle this job on an extremely rusty door. Enjoy the video, and let us know if you have any ideas for future technical how-to videos!

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  • 10 Tricks to remove that Stuck, Seized, or Stripped Bolt/Nut

    One of the biggest frustrations when disassembling a vehicle for restoration, or even repair, is the dreaded seized or stripped bolt. Stuck hardware occurs when a bolt or nut gets corrosion between the threads and they won't budge. Many times this leads to breaking the bolt off and having to drill and retap the hold or trying to remove it with a bolt extractor. I won't even mention what happens when the drill, tap, or extractor breaks off in the same hole!!

    Below are my top 10 ways to deal with getting these suckers extracted without wrecking the precious part they are in!

    1. Blunt Impact/Force- This is usually my first step when attempting to loosen stubborn bolts. I ALWAYS use this method before I begin removing exhaust studs from a cylinder head. There are a few methods for this. One is to hit on the head of the bolt in the center with a chisel or punch. Another is use an impact wrench/gun and hit it a few brief times in reverse and forward. Either of these methods work on the theory of freeing the corrosion bond between the threads by vibration or impact. It works sometimes on lightly seized bolts, but isn't a 100% winner every time. But keep in mind it can be combined with many of the other methods to help make the job easier.

    2. Heat- If you paid attention in chemistry class you would have learned that when you heat and cool metal it expands and contracts. The way that I have used in the past is to heat the head/body of the bolt until it is almost red hot. By doing this the bolt expands due to the heat, and when it cools it will contract thus breaking the corrosion in between the threads. A similar method is to heat the area around the bolt to make the hole it is threaded into actually expand and open up a little bit so that the bolt fits a bit looser and can be threaded out. Use of an impact wrench/gun helps when initially breaking it loose since the force from the hammering of the impact wrench breaks the corrosion apart as well. Use penetrants like Kroil or CRC Freeze-Off to aid in the removal process.

    3. Relief Cuts- This method is my "sure-fire" method for removing most stripped bolts/nuts. It isn't as clean/civilized as the others, but it is a heck of a lot faster! With this method you will be putting 2-3 cuts in the bolt head or nut. You want to cut just enough that you are almost all the way through the head of the bolt or the nut. You then can hit the cuts with a chisel and a hammer a few times, thus splitting the nut or bolt and relieving the tension on them. With nuts you can normally just split it off of the bolt, clean up the threads, and install a new nut. With bolts you can use some locking jaw pliers to grab the bolt head and turn the bolt out, usually the relief cuts will let the pliers squeeze the head of the bolt enough that you can turn it out easily.

    4.Rock the bolt- This is another one to try early-on in the process, and in conjunction with other methods. You want to slowly work the bolt/nut back and forth. I like to take a ratchet and loosen the nut/bolt a little bit until it gets a bit of tension behind it again, then go back the other way and turn it almost to where you started, before loosening a little bit further than last time. As you expose some of the hidden threads, you want to spray some penetrant on the those threads so that the penetrant works its way back into the hidden threads. It can be a slow process, but I've gotten some pretty stuck bolts out this way with a little bit of patience.

    5.Drill'er out!- This is the same concept as the relief cuts with a couple small twists or surprises that can occur along the way. I like to use this one as more of one of my last ditch efforts, or if the bolt has broken off flush with the surface. What you want to do is take a small drill bit and drill all the way through the bolt. This uses a bit of the chemistry a few of the other methods use. It heats the bolt by drilling it, and it also makes a hollow portion in the bolt so it can contract more as you attempt to remove it. I've had times where just drilling the bolt will allow the bolt to turn out quite easily. Other times you may have to keep stepping up your size of the drill bit with a drill index until you are just a bit smaller than the diameter of the bolt. At this point you may be able to carefully chisel or break the bolt apart in the hole. You can then extract the pieces and clean the threads back up with a tap set or a universal tap tool.

    6. Weld'er Up!- This is one that can be used if the nut or bolt head is so severely stripped you can't turn it with locking jaw pliers, or if the head is broken off the bolt. You can simply take a washer and a bolt of a slightly larger size and tack weld it to the bolt body. Once you have it tack welded, I like to fill the nut with weld and run a bead around the base of where it meets the bolt body. This allows you to put a socket on the bolt again, as well as puts heat into the bolt that will allow it to expand and contract, breaking some of the corrosion. I prefer to use a Mig Welder to do this job as it allows for a little more control than with a stick welder.

    7. Air Hammer/Chisel- This combines a few of the methods mentioned. But can be used when the bolt head is stripped. You basically chisel/hammer it so that the bolt loosens. Have had it work with moderate success, but needs to be on a bolt/nut that is an open area.

    8. Bolt or screw extractor- There are many styles/gimmicks. Some work, but many do not. They use hardened bits that grab into the inside of the bolt or nut to remove it. Many you have to drill a small hole in the bolt, then thread these in. Just whatever you do, DO NOT break the extractor off inside the hole, or you are in for a long, horrible process. Normal drill bits will not touch these, so you will need specialty drill bits to drill through them.

    9. Pipe Wrench- This is a pretty basic way to tackle a stripped bolt, and most everyone has a pipe wrench kicking around their shop. Tighten the pipe wrench down on the bolt/nut and as you crank on the bolt with the pipe wrench, it actually grabs harder onto the bolt head. Just watch you knuckles if it slips off!

    10. Reinstall bolts that surround the stuck bolt/nut- Sometimes a number of bolts in a area will hold a part on. Occasionally these are meant to be removed in a specific order. Make sure you check your repair manual for any installation/removal order. If none, I like to work from the center and work your way to the outside. Reinstalling some of the bolts around the stuck bolt may take some of the force off of the stuck bolt and allow you to remove it.

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