Hi all, I'm going to be cutting out and replacing my passengers front floor pan in the next couple of weeks, but will need to remove the box section that the front seats mount to.
I dont imagine that it will be a massive drama, but I thought that it be best to be for warned of any technical points that need addressing or usual pitfalls that people encounter.
Can I just cut out the passengers side, from the tunnel to the door, or is it best to remove the entire thing?
Any and all pointers would be great!!
mick

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If you cut out that section what are the seat going to mount on. The floor will be very very wobbly without it. That is a structural part of the car too.

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just removing it for the repair, then replacing it!
Its the proper fit pan with the chanel for the hydro lines. It comes out at least an inch behind the box section.

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Get some steel channel/angle/RHS whatever you have lying around and weld braces accross the car and lengthways BEFORE you cut anything out. Triangulate things to get maximum stiffness.

This will ensure the geometry all stays in the same place once you have replaced bits of structural steel with air. Then you can easily line up the replacement panel work and weld it in.

The braces will also help prevent warpage due to heat from the welding.

Once you are finished, cut the braces out and grind the area where it was welded back to a nice finish.

Job done.

For a good reference on what is possible when you brace it properly, check out this amazing thread http://www.ausmini.com/forums/viewtopic.php?t=30597&postdays=0&postorder=asc&start=0

cheers
michael

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There shouldn't be any real problems with removing and re-fitting the box section, however as mickmini has suggested, put a brace or two in first.

Keep in mind too, that if that part of the floor under the box section is OK and not in need of replacing, you can always trim down your new floor pan

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Thanks for the tips guys, like I said, I'm more than up to the task, I just needed to know of any pitfalls with a mini floorpan.



Someone once before did a repair on the same spot, except that they never cut out the old section. They simply welded a piece of flat sheet straight over the top of the damaged section, bogged up underneath and slapped on some paint.
I'm expecting nothing but the worst under the box section!!!

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Chuck Norris is the only person alive who can kick you in the back of the face!!
mooo, I'm a pig!

if your doing the inner/sill floor pan section that goes along where the box section is dont forget the jacking mount is also there.

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thanks bubba, the replacement pan has half the tunnel, and the inner sill.
Like I said in the begining, I was surprised how big it is!

_________________
Chuck Norris is the only person alive who can kick you in the back of the face!!
mooo, I'm a pig!