Replacing Floor Pan

[jperry1290]

I just cut out my rusted floor pan and plan on fabing my own floor from 16 gauge sheet metal. The old floor has ribbing and the new floor will be smooth, so what the best way to fill in the gaps where the two meet?

 

[BicksBronc]

Seam filler. If you are able to get them close the seam filler will make it look almost factory.

 

[Nightstick]

Do yourself and any potential future owner a favor and just buy an OEM style one. That or make sure you recess the area where the body mount goes. The PO of my "new" one used flat sheetmetal and left no hole so now I have cut out the area to change the body mounts. Just something to think about.

 

[Revelation]

I made mine flat, Body mount area is not recessed BUT I have a spacer under the floor and the bolt goes thru floor and is accessible.

Huge word of advise, add an extra cross brace under the floor, ideally add 2, one in front of and one behind the current brace, will help stiffen things up and cut down on the "tinning" noise.
Here is the profile I used.

(If you use the bed section as a pattern be sure to measure yours to ensure proper fit front to back.)

 

[Evian]

I did this last Summer. I picked up replacement panels from Tom's Bronco Parts. That company is awesome. They have good prices and the parts fit perfectly. Why reinvent the wheel when it is already available at a good price.

 

[jaroh]

I agree with Evian. I know that the design of a floor panel is not brain science, but why hassle with it if you don't have to. I just got mine from Tom's also, now if I can only find my bronco in the garage!!

 

[jperry1290]

I decided not to buy the pans from Toms or JGB because I was ablet to pick up a 5x8 piece of sheet metal for $40