Plan of Attack for Floorpan Replacement - Body Off or On?

[oscarsnapkin]

I’ve just read through every thread with the word “floorpan” in the title. I’m trying to figure out the best way to go about replacing both pans in my newly acquired ‘73. Obviously I think body off would be the way to go, if for no other reason it would make it easier to clean, rust proof and paint the frame/chassis. I have the car stored indoors at my father’s truck repair shop, where I can keep it indefinitely. I have plenty of room to work and to store the body while it is being repaired, and time is not an issue. What are the advantages and disadvantages to body on or off? From what I’ve read in the threads, it seems that aligning the body mount holes is the biggest area of concern with doing it body-off. Is there any other reason I am missing? Which brings the next question, how the heck does one make sure the holes align if it is done body-off? Not sure if I would trust my measuring/trimming skills. It seems like this is a fairly straight forward job, which isn’t as much hard as it would be time consuming. I know plenty of others have done this, I just want to make sure I don’t get in over my head. Thanks.
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- 1977 CEI Sunroof Bus 2.0L F.I. Hydraulic Lifters
- 1973 Thing

"It’s so easy to laugh, it’s so easy to hate, it takes strength to be gentle and kind."

[jakokombi]

I'd like to know too, I haven't looked in the Beetle forums for this topic. Have you?
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70 Sunroof Kombi
85 Motherfukinvanagon
73 Thing
72 Baja

[Dougster43]

I did mine with the body off. The pans pretty much will settle in where they will. I took about every measurement I could think of as an engineer, and at the end of the day there really wasn't much if any adjustment on where the pans sit - it was very obvious. As far as the alignment with the body mount holes - I had to make an adjustment on one of two of the holes in the pans with an angle grinder but really no big deal.

It seems like it would have been a much more difficult job with the body on but I'd be interested to hear from someone that did it that way.

[KAmes]

I have done half pans front and back with the body on multiple times over the years, have never actually done a whole side at once, and I have swapped the entire rolling chassis before. Without a doubt you can do a more complete job with the body off, however it's perfectly doable with the body on. The downside is you may find yourself welding from strange angles, you may or may not be able to properly bolt the pan under the napoleon's hat area in the front. I have cut it off flush and welded it there before. The upside is the project becomes simply fixing the floor, instead of tearing your car apart and all the difficulties that can come with that. It just depends on what you want, I do know the feeling of not wanting to launch into a forever project. I will say you can always start with the body on and if you don't like the way it's going you can still take it apart. Have fun with it whichever way you go.

[mondshine]

Just imagine the potential for "project expansion" with the body off.
You will probable find about a thousand other details that need attention when the chassis is completely exposed.
Have fun!

[Hot Rod Harp]

I did my rear pans with the body on to insure alignment. I purchased the "Bug Me Video" Volume #6 Floorpan Repair (1hr 45min).
It's for a Beetle but it works for a Thing. It explains Body On and Body Off techniques, replacing partial or half pan, tools and sealers,
just what I needed. I always try to save as much original metal as possible. And I did it outside.

BugMeVideo.com 800 662 0071

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74 Thing 1600DP
76 Westfalia 2.0L FI
69 Beetle 1500SP sold
88 Goldwing GL1500/6 sold


RinTinTin in Waldorf Astoria 1956

[perello]

i did a full floor replacement on mine by lifting the body a couple of inches

main reason was the lack of space, but all in all the work was smooth and alignement was granted
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Aug '58 pressed bumper SO23
1974 German Thing
1978 Bug 1200

[oscarsnapkin]

[c.davis419]

It really depends on your intentions with the car. With the body off EVERYTHING is so much easier to service or replace. Rebuilding the front end, replacing brake lines, rebuilding the pedal assembly, cleaning and painting the pan etc is so much easier that removing the 28 bolts becomes well worth it to me. Be prepared to slip down the rabbit hole as seeing everything you want to fix or replace becomes much more evident!
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1967 beetle
1974 Thing