I have started my project to convert my old Charger 2.2 autocross car into a hill-climb car. I know my floors were weak after pulling three years of street duty with my duaghter in salt-ridden Northeastern PA, but they were worse than I thought. The rear footwells will need to be completely replaced, but the front foot wells each have a 6"x6" bad area. What guage sheet metal should I use? I was thinking of welding in 16 guage steel, but need advice. I am concerned that even with the repair the structural integrity of teh car is too compromised. The body is solid and the new engine has only about 2000 miles on it, but that may be menaing less if the floors are bad. However, the floor supports and remainder of the unibody are solid.
I have used 20 gauge steel with good results, not replacement floorpans just flat steel for the use of these cars, spend as much time as you want shaping it until it is right or near enough for you, weld it in well and if it includes a seat support area, reinforce that area, I also use backing plates as per a race car so the load is spread.
Seat suppports are solid and separate from floor pan. Local place has 16 gauge and 22 gauge. I am concerned that 22 gauge is too thin. In past repairs I have welded the entire panel along the entire seem between the new panel and existing metal. I have seen people drill holes in the new metal and spot weld it. Is that strong enough?
Use the 16 ga. Cut out the rust, make a template of the hole in paper, put paper on the steel, cut out, hold steel over hold, trim a little here and there until it fits just right, bend as necessary, start tacking it in place, stop welding when it's solid, put light underneath and look for light shining through pinholes, weld pin holes, spray undercoating, paint. That's what I did for the Truck. For materials, I used a chunk of Ford truck hood I've been carrying around and an old PC AT case.
Um.....what thickness road signs do they use in PA?......
Our local scrap metal yard has street signs. They sell 'em by the pound, using the price for aluminum. Why aluminum? Because they are aluminum :) Doesn't weld to steel easy.
