First I went to the local Mustang restoration shop and picked up a replacement Dynacorn floor pan. The stamping is perfect, and a little longer on the firewall side to ease in fit. First, I layed the new pan in place and sat a cylinder head on top to weight it down. Then I used some black spray paint (the interior color is white) th mark off where the new pan will go. After the paint dried, I masked it off with masking tape to get a good clean edge so I could cut it out. I cut it out with a pneumatic cutoff tool and 3M green corps cutoff wheel. The 3M wheel lasted for the whole cut. I drilled out the spot welds with a 3/8" drill bit, the loosened them up with a chisel, once the pan was coming out.
Once the pan was out I layed it on top of the new pan and used some red spray paint to mark the spot weld holes for the new ones. Then I used the same 3/8" bit to drill out the holes.
The new pan layed in the hole perfectly, I left about 1/2" overlap of old metal to give me a base for the stitch welding. I tacked in the corners with .030 flux core welding wire using the Hobart 125EZ Flux Core MIG welder, then I started stitch about 1" apart all the way around the pan. After I finished the stitch, I started filling in the spot welds, using a rosette technique. Once the welding was done, I grinded down the welds and used a 3M seam sealer to finish off the seams.
After the seam sealer cured for 2 hours, I sprayed the firewall and floors with a red oxide caoting and allowed them to dry for an hour, then finished the job up with fith a coating of semi-flat black on all surfaces. Looks good as new and hopefully will last another 45 years.
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