As you can see from this picture, my poor GT6 has a floor made of swiss cheese and body filler. It’s more than a little depressing, and the one of the POs made a pretty horrific attempt to repair the drivers side with sheet metal and screws. We’re going to be fixing all that to make my car as good and strong as it was new (and stronger!). We’re going to start with the passenger side.
First steps here, as usual, are to cut out the cancer. This mean removing the entire passenger side floor pan and any weak metal attached to it. When I started cutting, it became clear that the rockers were more bondo than metal. And I mean way more. It’s bad. I’ve never seen bondo this thick on a car. In some places, it was literally 1″ thick and put on like they used a spray hose full of it.
Once I found all this, it meant even more metal removed. The inner sill and outer sill had a lot of rust. I ordered a new inner sill and rocker, and decided to repair the outer sill. I chopped the lower section of the outer sill off and replaced with the correct gauge metal, then hit it with a rust reformer/primer since it will be hidden once the new rocker is installed.
Then it was time to repair all the metal attached to the floor pan. The rear section had some rust holes and had to be repaired, and then it was just a matter of putting in the new panel from Steelcraft. I was hoping since these are “factory originals” they would fit without modification, but I should have known better. It took a lot of surgery to get it to fit like the original. Once I was all done though it fits very well and should be quite strong. After the car is blasted I’ll seam-seal everything up and we should be good to go!
