Not Original Floorpan Removal

[clockworkbox]

There is a lot of info on how to remove factory floorpans but not much about how to remove ones that have been replaced. I have a solid Ghia chassis that I am going to be using for my Beetle so I need to remove the Ghia pans but they are plug welded in. The plug welds are substantial and I don't think my air chisel is going to cut it. Any tips on how to remove plug welded pans without wrecking the flange? Any advice appreciated.
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'69 Beetle (pieces)
Learning the hard way is still learning...

[challomoner]

Cut them out next to tunnel flange and you should be able to see the welded spots, then it's just a matter of grinding through the welds. Pretty much the same procedure as removing stock pans just a little more work.

[viiking]

I have found a cheap electric file belt sander and 36 grit to be excellent on grinding down welds in a limited space. Much better than trying an angle grinder or expensive replacement Dremel cutting wheels. I buy full width wood belt sander belts and cut them down with scissors to suit the width of the file sander.

Out of all the tools I have for rust repairs, I have found the file sander to be fantastic at dressing down the front and backside of welds after bulk weld removal with an angle grinder without the worry of over-grinding the parent material. You have so much more control and the "contact patch" can be made small and sort of rectangular (to the shape of the belt). Plus you can get into spots you never can with an angle grinder.

Grind down the top of the weld with the file sander a bit, say half way, and THEN use the air chisel to cut through if you want to. Needs experimenting to see how far you have to grind through.

Alternatively you can use a carbide burr to do the same.
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1968 1500 RHD Lotus White Beetle since birth. In the hospital for major surgery
1966 Lancia Flavia Pininfarina Coupe - in the waiting room
Discharged: 1983 Vanagon, 1974 1800 Microbus,1968 Low Light,1968 Type 3

[VW_Jimbo]

I use 3 inch cut off wheels, on my air die grinder, to grind plug welds fast! I also stack the wheels to speed up the area to be ground out. Lately 3 wheels are working great with no bogging down!

Worth a try! Betting you will love it! I use this same setup for my primary grinding down of my welds, too. Followed up with a 36 grit flap wheel.
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Jimbo

There is never enough time to do it right the first time, but all the time necessary the second time!

[clockworkbox]

I have the tools you guys mention so I will see what I like best. Jimbo mentioned "grind plug welds fast" so that idea sounds like where I will start. Do you need a special mandrel to fit 3 wheels? I think I will use the file sander to clean things up at the end. I like the idea of cuttting down wide belt sander belts but I imagine it is hell on a pair of scissors! Thanks for the advice!
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'69 Beetle (pieces)
Learning the hard way is still learning...

[VW_Jimbo]

[clockworkbox]

Awesome, got a deal that included 10 disks. Should be here Saturday, thanks again!
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'69 Beetle (pieces)
Learning the hard way is still learning...

[viiking]

[clockworkbox]

In case it helps anyone, after grinding through about 7 plug welds, I discovered that the PO who installed the new pans never fully removed the factory pan's lip. I actually ended up using a chisel to pop the original spot welds and the plug welded metal came up with it. They cut the original pan right up to the lip, welded to the old pan metal and coated the seam with sealer so I couldn't tell there was an extra layer of metal there until I got into it. I also forgot to put on my gloves and ended up in the ER for 6 stitches to close up a bloody gash caused by whacking my hand against the metal I was removing. WEAR GLOVES!
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'69 Beetle (pieces)
Learning the hard way is still learning...

[jinx758]

@clockworkbox ...

I feel your pain, literally.
I usually leave a DNA sample on most tasks.
(I'm a no gloves kinda guy).

Never underestimate a prior owner's ability to cut corners.
Good karma to you for takin care of business.

Best luck ... stay safe(r)

jinx
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