Just wanted to show some of the work I've been doing on my Z to fix some thoroughly rusted floorpans and rockers. It is still very much in-progress but I'll try to update as it goes on. Hopefully it'll be of help to someone as a reference, or at least encourage folks to give it a shot. If you see anything wrong with the approach, please let me know!
Some quick background: The car is a '75 that I picked up in KY a few years back. Since then I fixed the fuel system and got it running, squared away the suspension (new bushings, shocks, springs, hubs, etc etc). But that is where my skill set ran out; never welded and never done resto work. Kept trying to find a shop to do the body work, but never had any luck. Then I moved and ended up close to a family member who happens to be a retired welder and enjoys doing resto/custom work on cars. Perfect chance to dive into the Z! So I bought a set of the Klassicfab panels and we dove in.
The floors/rails started off like so:
Driver's Side:
Driver's side outer rocker looking rough:
Passenger side:
The drivers side was worse, but both were pretty shot. There had been a previous repair to the drivers side floor pan in 2 areas, and the rail had been reinforced as well. But both floorpans were perforated in many areas and the rockers on both sides were pretty shot. The frame rails were also obviously shot.
First up, we got the car on blocks and welded in some braces.
Then we removed the driver's side inner and outer rockers and floorpan (scary initially to cut into the car, but that wore off quick), leaving the seat braces largely intact.
Then we welded together the new rockers (inner to outer), and welded the new frame rail to the bottom of the floorpan and tacked those in:
Then we welded those in.. or actually my Uncle did most of it because that is some EXPERT level welding; that steel is THIN
And then a quick check for door fitment.. should have done this after the tacks and BEFORE welding.. thankfully lined up fine (not perfectly lined up here because the bolts aren't tightened yet)
Next onto the passenger side.. same strategy; started cutting out the rockers and floorpan
Nice shot of the 4-layer 'sandwich' that is the rockers+pan+bottom of the A pillar:
And thats as far as I've made it thus far.. more to follow in the future. What a dirty and laborious job.. but also highly rewarding so far. I am learning a ton!
-Ben