Floor Pan Replacement

[david.mt]

TuxMan said:

Yep know what you mean , getting all the stuff together is a major feat !!!!! After 5 months I am still waiting for a few bits !!!!! Are you going next weekened be good to meetup for a chat ! Simon

I am planning to turn up - I would like to catch up and chat too - would like to bring my Nob but otherwise it will have to be some Pork.

[TuxMan]

Sounds good , will be there in the Noble ,need to sort out what I need to do floor bring me a few of the fixings you are going to use if you have some spare . Need to do it next as my floor leaks like a sieve !!!

[david.mt]

TuxMan said:

Sounds good , will be there in the Noble ,need to sort out what I need to do floor bring me a few of the fixings you are going to use if you have some spare . Need to do it next as my floor leaks like a sieve !!!

No problem - I can bring you a nice sample pack for you to play with - but there will be no BHP improvement

[worty]

Picked mine up from Jetsream yesterday after a service and a few bits & bobs. The floor had some work last year but needed a couple of the panels replacing this time. Hopefully should now be watertight.

Got to say Dave & Matt do a great job down there. It always seems like a new car when its had a service

Hope to see you lot at Mikes

worty

[david.mt]

worty said:

Picked mine up from Jetsream yesterday after a service and a few bits & bobs. The floor had some work last year but needed a couple of the panels replacing this time. Hopefully should now be watertight.

Got to say Dave & Matt do a great job down there. It always seems like a new car when its had a service

Hope to see you lot at Mikes

worty

I am hoping that I won't have to touch mine for a good few years once finished - otherwise I will have wasted hours and should have done the same as you and just thrown it at a garage who do such work every day.

[worty]

Was I dreaming or did you say you had a spitter for sale? I need a new one.

worty

[david.mt]

worty said:

Was I dreaming or did you say you had a spitter for sale? I need a new one.

worty

Sent you a PM so shout if you didn't get it.

Had a good day and the rear clam is now back on - also rebuilt the front end including the new Pro Alloy radiator and new hoses/pipes. I have coolant ready to refill so should be able to start and move the car this week (see separate thread).

Have a bit more cleaning of the centre chassis area before fastening the floor pan back but most of the work now done so should be just a case of cleaning certain areas and then bolting the cleaned panels back.

Have ordered some more neoprene strip and another 300 stainless screws as I seem to have used far too many already. I will have plenty spare so will bring them next week (if I get the car back on the road so anyone interested can see what I have used).

Too dark for more photos now so will have to wait until tomorrow.

[The devil]

have you a link to where you bought the screws

[david.mt]

The devil said:

have you a link to where you bought the screws

http://www.shop4fasteners.co.uk/

I drilled out the rivets with a 4mm cobalt bit and then I am using the 4.8mm stainless steel self drilling screws (as below) to refix the floor. I am also using some neoprene washers to ensure there is not contact between the aluminium and the fasteners.

http://www.shop4fasteners.co.uk/acatalog/Self_Dril...

[david.mt]

Well things are actually going back together reasonably well so will not doubt have a problem tomorrow (working from home ).

Managed to get the other flange so the tunnel access plate is finished:



And back in position (just a few bolts to replace!). You can see the neoprene strip that has been applied to the chassis here - I am just going to bolt the floor back onto this without any silicone etc and see if it is waterproof. Easy to drop and reseal if not.



Then managed to replace the coolant pipes and get the Pro Alloy radiator installed:





And then started to refit the easy floor panels:



The harder cabin panels will be started tomorrow. Still planning to get back on the road for the weekend

Edited by david.mt on Tuesday 23 March 19:34

[TuxMan]

Well done mate !! Looking very good , love the blue pipes :-) :-)

[david.mt]

TuxMan said:

Well done mate !! Looking very good , love the blue pipes :-) :-)

Thanks - had to follow your lead ...it is also a clear indicator of which have been changed once they get dirty again

[TuxMan]

Nooooooooo you are not aloud to get it dirty !!! :-) if it ever stops bloody raining I might get out in mine !!!

[david.mt]

I am desperate to get it out and get dirty

Working like an idiot to get down on Saturday (EDIT - or even Sunday ) - just stopped for a cup of tea. You may be please that the last post may be soon

Got the tunnel plate back in and connected - had to use the original ducting and the new silicone tube were no flexible enough to use - they were a struggle just to get them back to the heater box:





All the radiator and fans back in and working:



Most of the floor back on:



Last piece to fit but all cleaned up and neoprene tape in place:



And a treat for the Mrs so she can hear me coming

Edited by david.mt on Thursday 25th March 16:45

[TuxMan]

Well done Dave ,bloody good job !!! bet thats the most fun you have had with your clothes on in years !!! looking forward to seeing it sunday

[david.mt]

TuxMan said:

Well done Dave ,bloody good job !!! bet thats the most fun you have had with your clothes on in years !!! looking forward to seeing it sunday

Mmm - it's been challenging and rewarding that's for sure - not sure I would want to do it again though!

Just had to remove a dozen screws as they were straight into the footwell rather than the chassis . Anyway gave me a chance to use my stainless steel closed rivets - after putting in around 20 of these little buggers I can hardly move my arms .

The end is in sight though

[TuxMan]

Ha ha , put on your Xmas list a air riviter !!! Makes life alot less painfull :-). The great thing is you will not have to do it again as you have done it right the first time :-) and saved yourself a shed load of cash !!!!

[david.mt]

Well final post about this from me as all the bolts and rivets have now been finished. Stainless steel used throughout and the screws even had little neoprene washers - stainless closed rivets are a real bh to pop with a hand rivet tools when you are on your back.

Clearly the finshed floor is OTT for what was required but the car is now unique - shame no-one will really see it . Happy to move the content to Nobleparts as a record of how to remove and replace the floor but it's quite common sense when you start - just quite labour intensive to drill out the existing rivets and make sure that every replacement screw bites perfect as it has to create a water tight seal. I am gald I used neoprene strip rather than sealant as no way would I have been able to fasten all the screws in place before the sealant had gone off. I also think that the neoprene will be more effective as I know that it is even and covers every bit of the floor chassis.







So:

Floor pan removal, powdercoat and reseal - DONE
Clean up chassis and repaint areas - DONE
Tunnel cooling mod - DONE
Intake baffle plates removed - DONE
Replacement radiator and pipework - DONE
Replacement heatshielding - DONE
Exhaust wrap - DONE
New horn - DONE
Fingers shortened - DONE

Not one fastner reused - all replaced with stainless steel.

And finally.....got me Nob out



Did have an embarrassing moment at the petrol station when there was smoke bellowing out of the rear clam from the exhaust wrap as today was the first time I actually managed to get the car upto temperature. Fortunately is has stopped now but had me going for a moment.

Next installment - new carpets.

Edited by david.mt on Saturday 17th April 15:32

[GC1]

Well thats such a neat job, mine will never look that good.....!

[FUNKSTER UK]

That's a fantastic job, I would like to do mine later this year or next but I doubt very much it will be to that standard.
Where did you get the blue air hoses for the front from?
Matty