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

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

Products Used:
Wire Wheel: https://amzn.to/3lG8z6V
Corded Drill: https://amzn.to/3JDQvCs
Spot Weld Drill Bit: https://amzn.to/3TBy8CT
Bench Vise: https://amzn.to/42upl9T
4.5” Grinder: https://amzn.to/3nhGS53
Cutoff tool: https://amzn.to/42DINRF
Locking c clamp vise grip: https://amzn.to/3K1R9ej
Aviation Snips: https://amzn.to/3LMe3b6
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Ball peen hammer: https://amzn.to/40evZzA
Chisels: https://amzn.to/3yZHCy2
Switchable On/Off magnet: https://amzn.to/3X45sD1
Weld thru coating: https://amzn.to/40xiw5I
Duplicolor Prep Spray: https://amzn.to/3K2wEhL
DupliColor Self-Etching Primer: https://amzn.to/3lku7mH
Dynatron seam sealer: https://amzn.to/3TBzoG7
welding blanket: https://amzn.to/42M0lLs
Lincoln 110v Mig Welder: https://amzn.to/3LKFORe
Auto Darkening Welding Helmet (recommended): https://amzn.to/3nleH4U
Plasma Cutter (optional): https://s.vevor.com/bfQa6g
Fluid Film aerosol cans: https://amzn.to/3e1Sh1X

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.

Rusty 1980 Toyota Pickup Truck Long Bed(s) Build Intro: https://youtu.be/fzanHIhF9-4

1980 Toyota Long Bed Rusty Cab Floor Comparison: https://youtu.be/hxMLLtuqnJo

My used OEM Toyota Parts for sale: http://yota.6thgeargarage.net/

I don’t have Patreon or ask for donations, but you can support the channel with some rad ‘Yota gear from my store: http://6thgeargarage.net/merchandise/

Instagram: 6th_gear
facebook.com/6thGearGarage

Some other Toyota videos you may find helpful:
Remove 1980’s Toyota Pickup/4Runner Dash Pad Cover: https://youtu.be/oZD-g4RfdUo
Rebuild Front Knuckles: https://youtu.be/1AjhM4aF_M8
Restore/Fix/Repair a Cracked Vinyl Dash: https://youtu.be/XB9GKLRHYNM
Remove Toyota Truck Rear Glass Window: https://youtu.be/0CKQC8hrOOE
How to clean/Restore Toyota Pickup/4Runner Door Panels: https://youtu.be/SrkyU1dGEh8
Toyota Door Disassemble: https://youtu.be/JWifUB0VQPc
Rebuild front knuckle & replace birfield joint 80 Series: https://youtu.be/pxMACmhY-3w
Remove an Entire Toyota Rear Axle Assembly: https://youtu.be/MIQEsumrEHQ
Install/Upgrade to V6 1″ Master Cylinder on 4 cyl Toyota: https://youtu.be/P2DT0RHI8K8
Install Toyota Rear Axle Bearing, Oil Seal – WITHOUT a Press: https://youtu.be/6LdUhST3aIg
Replace Toyota Drive Shaft Center Support Carrier Bearing: https://youtu.be/CbzyPUmBiEU
Trail Gear Hi-Steer install: https://youtu.be/vJqFHQq9Ni0
Toyota Pickup Fiberglass Bed Review/Comparison: https://youtu.be/TuwqEFHvifo
How to Properly Repair Rusty Frame: https://youtu.be/VkKxIEPKUAQ
Repairing Toyota Frame – Cut Out & Replace Metal: https://youtu.be/5DY-SfQZyZU
Fixing Floor and Rocker panel rust: https://youtu.be/7Xkdnrsa62A
Remove Headliner in Toyota Pickup Truck: https://youtu.be/HP9uAocDztQ
Remove Toyota Pickup & 4Runner COMPLETE Dash: https://youtu.be/yKG_F30MdQE
Toyota 22RE Engine Teardown: https://youtu.be/muBeyKgP5gY
22r Compression Test: https://youtu.be/v7EdRwCW9Fs
Remove Toyota 22RE Engine & Transmission: https://youtu.be/9utG8PChbc4
Toyota Pickup/4Runner Vent Window Conversion: https://youtu.be/nDJM9MBk4-k
Toyota 4×4 Transfer Case Rear Flange Oil Seal Replacement: https://youtu.be/a-_c7jKx7uc
Replace Pinion Oil Seal in Rear Diff: https://youtu.be/0xGH8J9YJYs
Remove Door Panel: https://youtu.be/6yAXzWO_i6s
LED Headlight Conversion: https://youtu.be/-V9lLASMNxI
Repairing Toyota Frame – Cut Out & Replace Metal: https://youtu.be/5DY-SfQZyZU
Breaking a Rusty Toyota Frame in Half: https://youtu.be/MZEADsA92UA
B-Pillar Trim Removal & Install: https://youtu.be/6urbZ2BQ24k
How to disassemble Vent Window: https://youtu.be/7-DoHb2y9qM

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Comments

Scrapy 5672 says:

Done better Job than most professions do they charge 100's hr to do the same, never finish keep milking the customer till they run out money, very nice work. Better you make the patch panels look the better your work will be when finished.

Shannon Boatright says:

Awesome!! Great job I’m glad I live in South Georgia I don’t have to worry about all that road salt

mike donnarumma says:

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

Green Isle Rustproofing says:

Great video, very motivating as always. I have a similar patch to do on the 87 4runner in my snow plow video, it’s by the body mount but only about the size of a fist

Patrick Kissman says:

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.

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