Floor Pan Replacement Planning (67 up pans in 65 Dart)

[Beams]

I badly need to patch floors in my 1965 dart. Came across a full set of 67+ Laysons a body floor pans for a good price. I know they aren’t an exact fit, and especially because I have the 4 speed hump, will likely need extra massaging. However, it should be a decent start—I’ll take it one step at a time, and may patch where I can, instead of full replacement.

I get a couple hours a weekend while the youngest naps. Could spend time at night, too. Just figure that once I start, the car is immobile for a bit. If I thought it would take too long, I’d probably take it somewhere where it’s out of the way. Just harder to work on it, when I have to leave the house.

A “for-fun” question: On average, how many hours would you plan to spend patching/replacing all four floor pans? Including prep, removing interior, patching, sealing, and painting. I’d consider insulating, installing carpet, etc. as a second phase.

Oh, also, this would be my first big welding project. I’ll probably double the number of hours everyone else takes. Pictures of new pans just for something to look at.

 

[65 Dartman]

I did the 67-later pans about 25 years ago in a 65 Dart as that was the only thing available for an early A. they turned out OK - not the prettiest but serviceable. Fast forward to now - EXACT FIT early A floor pans are now available. I used them for both fronts and passenger side rear on my 65 wagon and so much easier than trying to make/modify later pans fit. If it were me I’d sell what you got and use the correct pans

 

[Beams]

Thanks @65 Dartman

I agree that would be the route that makes the most sense. I’m not replacing today or tomorrow, so have time before I commit.

Exact fit plans would be cleaner, quicker, and easier. I’m really trying to plan for time.

I’m assuming I’ll probably take a couple hours in interior removal and cleanup (2 hours). A couple hours each pan (8 hrs), couple hours in sealing and painting (2 hrs). Then a couple of extra hours (2-10 hrs) because I’m slower than I think I am.

 

[DartManPlum340]

I did the 67-later pans about 25 years ago in a 65 Dart as that was the only thing available for an early A. they turned out OK - not the prettiest but serviceable. Fast forward to now - EXACT FIT early A floor pans are now available. I used them for both fronts and passenger side rear and so much easier than trying to make/modify later pans fit. If it were me I’d sell what you got and use the correct pans

Thanks @65 Dartman. I did a quick search, found these: 1962-1966 DODGE & PLYMOUTH A-BODY COMPLETE FLOOR PAN KIT-4 PIECES But, does anyone make a full pan?
Rick

 

[Rick@Laysons]

I replaced the front floor pans in Dave Layson's daily driver '66 Valiant using the 67+ patch panels. It's not as hard as everybody makes it out to be. Just be patient and work with forethought.

Figure about 8 hours total for the two front pans, I'm gettin old and just not as fast as I used to be(Thank You arthritis!)

 

[Beams]

I replaced the front floor pans in Dave Layson's daily driver '66 Valiant using the 67+ patch panels. It's not as hard as everybody makes it out to be. Just be patient and work with forethought.

Figure about 8 hours total for the two front pans, I'm gettin old and just not as fast as I used to be(Thank You arthritis!)

Thanks, Rick. I’m sure I’ll shed some tears at some point.

 

[RogerRamRod]

You think you’re slow, I take everyone’s hours estimate and convert it to weeks

 

[Beams]

Here we go…almost a year later. Look for the next update in 11 months…

 

[Beams]

Rears should work just fine. Front will be fun.

 

[Demonracer]

I wouldn't worry too much about how many hours, everyone works at their own pace. Pick a starting point and begin, if your frustration level starts to rise step away. Take time to let your frustration level dies down and begin again.

 

[Beams]

I wouldn't worry too much about how many hours, everyone works at their own pace. Pick a starting point and begin, if your frustration level starts to rise step away. Take time to let your frustration level dies down and begin again.

Thanks, Demonracer. I’m okay if it takes time. I’m just looking forward to learning something new.

 

[Demonracer]

Oh, you will learn a "lot" of new things including words you don't normally use, LMAO

 

[Beams]

Single picture for this evening’s update. Lots more cutting… just taking it a bite at a time.

 

[Beams]

Another two hours of cutting and fitting. Description of “not hard, just time consuming” is accurate so far. But this is just one rear pan.

 

[Beams]

This one is as good as done!

 

[Beams]

Am I a glutton if I don’t finish welding this pan and move on to others?

 

[Beams]

Turns out I had the front pans on the wrong side during my very brief mockup. Driver will still be interesting because of the 4 speed hump. Passenger side looks way less scary.

 

[toolmanmike]

Thanks @65 Dartman. I did a quick search, found these: 1962-1966 DODGE & PLYMOUTH A-BODY COMPLETE FLOOR PAN KIT-4 PIECES But, does anyone make a full pan?
Rick

$600 for the right pans is the way to go. Those ABS pans fit well as per the guys here that have used them.

 

[Beams]

I have no complaints so far. I picked up my pans used for $200.

My guess is that any additional work I’ve had to do/will have to do won’t make up the monetary difference.

At the end, it may be absolute garbage and I’ll eat my words. I’m pretty pumped actually. Even if it doesn’t turn out perfect. I’m making mistakes and cool with that.

 

[RustyRatRod]

Knock it out. Use what you have. Dang right. You're doin a good job.

 

[Beams]

An update because validation (or something) keeps me going.

Front passenger is tacked in. I’m going to try the cut and butt method. Found a key issue with the 67 pans: in the replacement pans, the front rocker area jumps up. Stays flat in real life. I made it work. Not great, but better than the rotted floor that was there.

Cut out the driver rear. It’s bad. I’m going to end up cutting a bunch to find good metal. I’m burnt on this, but am counting on it being worth it once done.

 

[Beams]

Played hooky today to work on pans.

Three pans almost done. Front driver pan is next. I’m tempted to just buy the right pan for this one. But I’ve also come so far.

 

[Beams]

More progress yesterday. Finally started front driver’s side in earnest.

What’s the best procedure to separate the floorpan to firewall seam? I have some spot welds drilled out. Are there more underneath?

 

[RogerRamRod]

There's a bunch along the seam itself. Not sure how many you can get with engine in place, but maybe some from above, some from below. I had my car stripped, & on a rotisserie. You might have to cut near the junction and butt weld the new to the old, or maybe a combination. I'd say, get as much as you can, mull it over and see if you can come up with ideas to get some more, see if theres any more input from here. Maybe do a couple other items to see if any ideas pop.
Looking at doing that job with all that you are trying to work around just makes me shudder. I feel for you.

 

[Beams]

There's a bunch along the seam itself. Not sure how many you can get with engine in place, but maybe some from above, some from below. I had my car stripped, & on a rotisserie. You might have to cut near the junction and butt weld the new to the old, or maybe a combination. I'd say, get as much as you can, mull it over and see if you can come up with ideas to get some more, see if theres any more input from here. Maybe do a couple other items to see if any ideas pop.
Looking at doing that job with all that you are trying to work around just makes me shudder. I feel for you.

Thank you! I appreciate it. I’m ready to be done, but the long breaks between are probably helping to keep me from going crazy.

Looks like this guy just took the angle grinder to the seam at the 15 minute mark. And goes back with the air chisel and more detail at 26 minutes.