I’m tackling floor panel rust on my 1965 Thunderbird project car and looking for some guidance. This classic is a driver, not a showpiece, so my aim is solid, functional repairs in keeping with the original style, prioritizing practicality and cost-effectiveness. The driver’s side front floor pan has a bolted-on patch over a rust hole, and the passenger side is soft, indicating both need replacement. Floor panel replacement is new territory for me, and I have a couple of key questions before I start this repair car floor panel project.
Firstly, given the Thunderbird’s unibody construction, is it crucial to replace floor pans one side at a time to maintain structural integrity? Or can I remove and replace both sides concurrently? I’m keen to minimize the repair time to a single session with a friend who can weld, but structural safety is paramount. The pinch weld rails seem to be in good condition, and the powertrain will remain in place during the repair.
Secondly, I’m researching replacement floor pan panels. Classic 2 Current offers options at a significantly lower price point than Mac’s, but their panels appear simpler and less contoured than the originals. While cost is a factor, I’m wary of potential fitment issues and extra work with less precise panels. Are the more affordable Classic 2 Current panels a viable option for a driver-quality repair, or is it worth investing in the potentially better-fitting, albeit pricier, panels from Mac’s?
Any advice on these questions, or general tips for car floor panel repair on a unibody classic like a 1965 Thunderbird, would be greatly appreciated.
