Floor Panel Repair
Channel: Mike Restores an FJ40
Date: 2020-02-10

The driver's side floor pan was rusty and it needs to be replaced. 

You can buy pre-made floor pans, but I had a sheet of steel the right size and thickness, so I decided to make my own. 

I found three sources for pre-made floor pans.  Good ones cost about $190 before shipping and tax.

https://www.coolcruisers.com/floorpanfron3.html 

The floor is flat, but there a beads pressed into the floor to stiffen it. I could have simply used a flat piece but I thought the extra stiffness would be worthwhile, so I decided to try to add the beads myself.

I made a form the right size and shape from another piece of metal then used a ball-peen hammer to push the metal into the form. 

The result is a little bumpy, but I'll try to work that out before I weld it in. 

To prevent this from getting rusting again, I plan to use bed liner or something similar.  This produce a durable, slightly bumpy finish that will stand up to abuse better than factory paint job  (and hide any imperfections from my handmade beads). 

I also have to make some repairs to the inside of the sill and the A pillar.  I'll weld flat pieces in.  The result will a be as good as new floor with a durable finish.