How to: Repair/Replace Rusty Floor in Vehicle - Complete Guide, Start to Finish

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Cutting out the rusty floor in a vehicle and welding in a replacement floor pan or custom cut sheet metal is a long and tedious job. I documented the process from start to finish to offer a complete guide. My vehicle is a very rusty 1980 Toyota pickup, so the rust holes also went up the inside walls of the cab. I used a reproduction floor pan, but also had to fabricate a lot of additional pieces from sheet metal because the floor pans do not cover all of the areas affected by rust.

Instagram: 6th_gear

Some other Toyota videos you may find helpful:

[ziggybaker]

I know this is a year old by now, but WOW what a JOB! I can't imagine doing all that work; some people would say it's not worth it but I commend you for tackling it! Very informative and fascinating video. I just recently decided to get into cars so stuff like this is very appreciated! So from one Ohioan to another, thank you!

[josephobrien]

I am 62 and always wanted to restore an old car. A few months ago. a friend gave me a 1940 Plymouth Sedan. I'm going for it and your videos are going to get me there. Thank you.

[aerialrescuesolutions]

The classical music is awesome, a very nice touch. Excellent video

[paulallenjones]

I really like your choice of music. I'm trying to motivate myself to do the floor pans on my Ford Super Duty.

[Nordkampf]

Wow man. I thought my truck was a goner but seeing you do this really gave me the motivation to get at it. Gave alot of good advice too when it comes cutting out rusted sheet metal. Can't thank you enough

[mikedonnarumma]

you took what seemed like an impossible task and nailed it, mate your a legend and an education thanks

[retro_yota]

Here is a tip for easy sound deadening removal. Get a bunch of dry ice, pack it on top of the sound deadening. Once it's cold remove the ice and tap it with a hammer and it will shatter and pop right off.

[grayrider-]

Hello 6th Gear! I especially like that you took the time to talk about the value of one tool over another, like the aviation snips versus the tin snips for cutting the sheet metal. Sharing your knowledge here is very much appreciated. I am a very amateur sheet metal welder, (MIG), myself and seeing you weld your sheet metal without too, too many "blow-throughs" was encouraging. I have a 40 year old Volvo "Brick" to do some rusty floor repair on, and your video has really inspired me to have at it! And like you indicated, after you clean up the welds, use the seam sealer over the etch-primer in order to seal up any pinholes from moisture creeping in from the other side. And by the way, your bloopers at the end are hilarious. It was great to see your sense of humor. Keep up the GREAT work: your videos are so down-to-earth, informative, and entertaining - all rolled into one! Thank you very much!

[camilogonzalez]

Awesome tips. I'm about to start the restoration of my 1993 Fox Body LX Convertible and I thought it was better to trash it, but you gave me hope. Sorry, but my car is not even close to that truck. I heard people talking Sh!÷ . Now I'm getting my baby back on the road.

[milnermoss]

thanks you for putting this video together. What i like about your approach is, " you work with what you have" and don't use any fancy and expensive tools to get the job done. Well done mate!!

[khookieman]

this is prob the most realistic situation that most people experience in my opinion.... many other youtube channels that claim (respectfully to them with no prejudice) they are no mechanics/craftsmen etc and were not so long ago fixing cars in parking lots and yet when they show a repair, its not just seamless, but it it feels like they have done it a million times prior, ...their "fist attempt" at it fits /goes in smoothly like a glove., in short they get it right the first time around, This guy, however, shows that for every fitting of something once but the need to remove it 10 times to get something else done prior, or for example how other people just seem to minimally weld something with the least amounts of spot/tac welds, while I seem to need a million other jigsaw puzzle pieces and a gazillion welds to plug up a hole, …you get the point...anyway I speak for myself, maybe because I ain't so talented, (or suggesting for that matter this person in the video isn't) but I certainly have the same experience and can relate. Not saying that it should be so for everyone else just that for once I don't feel envious and jealous of how other people get it right the first time round or very quickly (granted I know its video editing magic...but still)

[madcat]

It would have been nice if we had people making replacement floor pans for old cars in my country.

Thankfully, we don't have road salt due to know snow, except on mountains.

Satisfying video to watch, the time flew by.

[doobyboy]

I did the same thing on my Ford Mustang but didnt ever use welding... I used automotive Floor pan sealer and rivets... Great job !

[ian.lwilson]

I don’t feel so bad about the rust in my 1985 Ram 50! Wow what a mission to repair that! PS a sharp counter sinking drill bit is way more efficient than a step drill. Cool project.

[alain]

Great channel! Keep up the good work. Following along since I’ve got an 82 4WD short bed that’s undergoing a restoration. Learning a lot from your videos. Thank you

[andrethomas]

Thanks for the video! I'm starting work on my '84 Ramcharger this weekend, and this video was a big help.

[marchallaert]

You sir have the patience of Job. That alone is worth the time to watch this video. Your fabrication with basic tools is a great example of what can be done without all the conveniences of a full scale shop. Good job all around and your welding is great. As someone who has done a bit of this type of work myself your fabrication and attention to detail on such a rusty repair is very good. 👍🔨

[DavidAKTA]

Excellent how-to video! Very Informative and I like how organized it is. Videos on auto metalwork by others commonly have long boring moments as they ramble on or try to figure out what to say or do next. Not yours. I was looking for tips as I prepare to patch the floors in my '81 Trans Am. It has very small amounts of rot not nearly as bad as your truck. Very nice music choices too. Liszt, Rosini, Tchaikovsky were nice to hear. Very soothing as I go out to my garage now and try to patch as well as you. Thanks.

[floridamanfishing]

Great video got me inspired. I am going to be doing the same thing to my 85 Chevy. Camaro driver's side floor pan is Pretty bad I was a little afraid to tackle this project myself. But aint not too but to do it rigth also I do have a Lincoln welder 140 mig that i Purchased from home depot so i am ready your video is definitely going to help me out. Great job sir

[MrHarleyreinke]

Brings you back to the eg days huh lol. I swear I feel like I've grown up with you since the forums days lol