Dealing with a rusty car floor pan can be a daunting task, especially when you’re looking at extensive damage like I am on my El Camino project. I’ve got brand new replacement panels ready to go for the front and rear floor sections, which is a great start. However, the rust goes beyond what these panels cover, meaning I’ll need to incorporate a center section from another G-body to properly bridge the gap.
Now, here’s where I’m hitting a bit of a roadblock: figuring out the best way to weld these panels in. I’m wading through a lot of conflicting advice, particularly when it comes to butt welding versus plug welding. Butt welding is often touted as the “best” method, but honestly, it sounds incredibly challenging and risky, potentially warping the new panels. On the other hand, plug welding seems quicker and simpler, and I’ve seen tutorials suggesting it. One tutorial I looked at involved flanging the replacement floor, which adds time but seems like it could simplify alignment. My main worry with plug welding, though, is whether it might trap moisture and lead to rust coming back down the line.
This repair isn’t about winning any beauty contests. This El Camino is going to be a driver, maybe even see some action at the Challenge. The floor will be covered up anyway, so my priority is a solid, durable repair that will last and prevent future rust issues.
So, what’s the recommended approach here? If you have any tutorials or videos that could guide me, that would be fantastic!
