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Thu Aug 15, 2013 1:44 pm

Back to work...Going to drill small holes (guidance from Brett) and attach the floor with screws first. That will draw it tight for gap free welds and will also allow me to make sure everything is going to go back in correctly before I do the final welding. When I'm ready to weld, the screws will come out one at a time, get drilled larger, and get puddle welded. Brett pointed out tat this way, after doing a weld, I can pull out the adjoining screws and see if my weld is holding too:

Thu Aug 15, 2013 1:46 pm

Removed the funky green primer from where I'll be welding. Yeah...I know...forgot the area behind the shifter. I got it after the shot was taken. Did the other side as well.

Thu Aug 15, 2013 1:49 pm

Where the floor meets my seat pedestal, there are some areas I'll have to patch, but it's not bad enough to warrant any major replacement panel in my totally inexperienced opinion. This will be my first attempt at patching/welding from sheet stock.

Thu Aug 15, 2013 1:55 pm

So...that's where I'm at. I plan to patch up the pedestal area where it will meet the floor, while I'm waiting for my most recent order of green stuff (A-pillars and lower dog legs). This is definitely more involved than I'd anticipated. Huge job getting everything out, cleaned up and ready for replacement floor. It has me also restoring / fixing stuff I removed and also stuff I now have easy access to. Just changed out the master cylinder seals to the reservoir that were shoddy. The PO had welded some incorrect accelerator pedal onto the floor, so I now have everything new going in from the bracket (to be welded on), to the pedal, and everything in between. Too much else to list here. Can't wait to get things back together and feel that solid new floor under my feet! Maybe next week this time.

Thu Aug 15, 2013 2:03 pm

Very cool man, enjoying the progress, pics and write up. That does seem like a good idea about screwing it in first too...

Fri Aug 16, 2013 8:46 pm

Just checking out this thread:

http://www.thesamba.com/vw/forum/viewtopic.php?p=6806016#6806016

The guy is welding in his floors from underneath. The lack of drilling, screwing down, puddle welding and grinding off welds is VERY tempting. Whattaya think the downside is? Opinions? Experience?

Fri Aug 16, 2013 9:08 pm

kenshapiro2002 wrote: Just checking out this thread:

http://www.thesamba.com/vw/forum/viewtopic.php?p=6806016#6806016

The guy is welding in his floors from underneath. The lack of drilling, screwing down, puddle welding and grinding off welds is VERY tempting. Whattaya think the downside is? Opinions? Experience? while this works fine for some of the floor the front and rear edges still need plug welding

Fri Aug 16, 2013 10:45 pm

kenshapiro2002 wrote: Just checking out this thread:

http://www.thesamba.com/vw/forum/viewtopic.php?p=6806016#6806016

The guy is welding in his floors from underneath. The lack of drilling, screwing down, puddle welding and grinding off welds is VERY tempting. Whattaya think the downside is? Opinions? Experience?

I'm not a welder but my thoughts when I saw that were:
1. It doesn't look that good compared to doing it from the top with holes.
2. It seriously looks like he didn't wire wheel some of the areas he welded to, won't that make the welds crappy?

Fri Aug 16, 2013 11:33 pm

everett, while you may not be a welder, you make correct assumptions. by not completely cleaning the metal you end you with a 'crappy' weld for sure.

do NOT weld from underneath, this looks like shit and is half assed.

but of course, only my $0.02

Sat Aug 17, 2013 1:24 am

I would not do that if it were me...It's not that much more work to do it right. That thread has a lot of questionable work in it and you shouldn't reference it when doing repairs. This is coming from a person who has actually done some body work and knows how hard it is...And I would be the first person to point my mistakes out to someone if they were looking at my bus.

Just don't forget to drill the holes for the frame rails like I did...I am gonna have to go back and drill them out with a spot weld cutter so I can weld it down correctly.

Sat Aug 17, 2013 10:21 am

I'm slowly in the process of removing my front floor, it is no picnic. I too tried the spot weld cutter and didn't care for it.

Yesterday, I tried your approach. I removed/cut out the metal all around where the floor was welded. Then I hit the remaining metal sections with a flap disc exposing the welds.

I followed up with a chisel and hammer and was able to separate the remaining metal. I found that even when I was careful, I still made a few small slices in the good metal. I'm pretty sure the little slices will easily weld up even for a novice welder like me. The toughest part for me is where it is welded to the front inner panel.

I've come to the conclusion that there is no easy way to remove the front floor, all the different methods/approaches have pros/cons.

Thanks for the detailed thread.

Sat Aug 17, 2013 11:08 am

Daniel G wrote: I would not do that if it were me...It's not that much more work to do it right. That thread has a lot of questionable work in it and you shouldn't reference it when doing repairs. .

Just look at that corner fitment in the thread. Plus everything looks overlapped and stitch welded. Not butt welded fully like it should be.

Mon Aug 19, 2013 4:35 am

The easy way is tempting, in the end I would try this way.
I also install two bolts at shifter base.

These are the welds over frame.

Mon Aug 19, 2013 6:01 am

And THAT is why I'm "Bretting" my floor in! :D

Mon Aug 19, 2013 10:21 pm

That or sheet metal screws...Just don't get lazy like I did and leave half of them in so you can drive the bus. I also have to replace the lower seat pedestals on my bus though so I will finish welding my floor in then.

Also make sure you put the pedal bracket on the right way before you weld it and install the pedal. Ask me how I know. :lol:

Tue Aug 20, 2013 6:32 am

Daniel G wrote: That or sheet metal screws...Just don't get lazy like I did and leave half of them in so you can drive the bus. I also have to replace the lower seat pedestals on my bus though so I will finish welding my floor in then.

Also make sure you put the pedal bracket on the right way before you weld it and install the pedal. Ask me how I know. :lol:

I'm patching mine right now. Just needed to add some material to the "lip" that goes under the floor. Then I'll be patching the A-pillare and lower dog legs with the funky green that's supposed to arrive from Bogota tomorrow. Hope to have the floor in next week. I'll post pics as soon as install begins. I didn't want to add in my patching pictures as they are not directly related to this thread. I want to keep this a "floor replacement" thread.

Mon Sep 09, 2013 10:08 am

Still working up to getting the floor in...haven't forgotten. I've replaced the left side A-pillar and lower dogleg. I should finish up the right side A-pillar tomorrow. I'll get back to the floor if it kills me. Lesson taught here? Replacing "A", usually results in doing "B", "C" and "D" if you're conscientious.

Mon Sep 09, 2013 10:16 am

I just saw in another thread about using a scissor jack to hold the floor down while welding:

Might help!

Thu Sep 12, 2013 10:27 am

Last dogleg replaced! Floor goes back in starting Monday.

Thu Sep 12, 2013 2:48 pm

kenshapiro2002 wrote: Last dogleg replaced! Floor goes back in starting Monday.

Didnt happen without pictures Ken. :D