Cab Floor Repair Panel
As the foundation of most of the vehicle's structural and mechanical components, the vehicle's floor pan should always be free from rust. But because of its location, the floor panel is always prone to elements that cause rust and corrosion. Since this panel is usually covered by carpet and mats inside the vehicle's interior, it may take you a while to notice when rust is starting to eat it up.
If during your inspection, you've found out that your cab floor is already rusted, waste no time! Cut out that rusted part and replace with a cab floor repair panel. Whether you're dealing with a rear cab floor repair panel or double cab loading floor repair panels, here are some tips to bear in mind to ensure your safety while working and to help you remedy the problem faster:
Tip #1: Remove all the components that may get in your way.
To make your DIY floor panel replacement faster, it is necessary to take the carpet out of the cabin. Those who are working on the driver's side floor panel have more tasks at hand as they need to remove the driver's seat and the pedal cluster. It's also necessary to disconnect the clutch cable.
While you're working with your floor panel, it is a good idea to ask someone to wash the carpet and lay it out in the sun to dry. The heat of the sun won't just dry the carpet, but it will also help eliminate foul odor.
Tip #2: Pre-fit the cab floor repair panel.
Put your floor panel on top of the damaged area and, using a marker, trace an outline of the replacement panel on top of the original panel. Make an exact inner line that's one inch apart from the original line that you've made. That will serve as your guide when cutting the damaged panel. This will ensure that the edges of the replacement cab floor repair panel will lie flat against the remaining parts of the floor panel and that the new panel overlaps the old one by an inch. This one-inch overlap will provide you with enough area for drilling holes where rivets will be inserted.
Tip #3: Use protective eyewear when working with power tools.
When installing cab floors and seat mounting panels, you may need to use some power tools, such as drill. You see, even a simple act of sawing wood or hitting a nail with a hammer can produce small debris that can be dangerous once they get in contact with your eyes. Eye protection in the form of safety glasses or goggles is actually a minimum requirement. Depending on the hand tools you'll use, you may also be required to wear cut-resistant gloves to protect your hands from abrasion, cuts, and repeated impact.
Tip #4: Make sure to cut and replace the entire corroded section.
The actual size of the rusted part of the floor may not be visible especially if the floor has already seen better days. You can use media blaster to clear the panel off any paint and other debris, so the rusted area will be completely revealed. Cutting the rusted panel can also be tricky, so use only the right tool such as an angle grinder fitted with a cut-off wheel. Cut out the entire rusted part of the panel. Failure to do so will just shorten the service life of your new cab floor repair panel as the remaining rust buildup will slowly get into it and eat the panel up.