Floor pan to kick panel Union? - The 1947 - Present Chevrolet & GMC Truck Message Board Network

custom10nut · 09-11-2022, 09:25 PM

Today I really tore into my truck to find out what kind of patching I need to do the repair the rust.
I already posted abou what I’m doing to fix my Rocker Panels, and will update that thread with pictures.
My question is this:
Where the Floorpan meets the bottom of the kick panels,
How is this attached? Are they welded together, or tacked together and then sealed with seam sealer (Which it appears to be)?
My plan is to cut out the old, fab patches, and Buttweld them in, but I need to know about securing the bottom part.
Thanks is advance

jumpsoffrock · 09-12-2022, 12:10 AM

I was fiddling with that area a few months ago but never cut through it. From what I can tell the floor pan bents over ┌ on the drivers side.
Then in my humble opinion the kick panel is bonded first with a layer of special seam sealer, maybe to handle high temps. Then it was pinch welded.

custom10nut · 09-12-2022, 08:04 AM

I was thinking the same thing.
Both sides of mine have small rust holes, about the size of a bic lighter.

I plan on cutting all the rust out, fabricate a patch, and butt weld it in.
Then I’ll seal it with a bead of body sealer.
To me, it appears the truck came from the factory like that.
I’d sure like to see a few more responses to confirm this.

**Jason Banks** · 09-12-2022, 08:25 AM

Yah, it's a layer sandwich down there. Edge of the floor pan is bent down, kickpanel comes down beside it and then you have the lower a-pillar on top of that. Spotwelds everywhere. The ones I have seen had that crummy foam seam sealer.

I don't think it would be a crime to just weld it up on the inside though, since it won't be visible after the carpet is there.

custom10nut · 09-12-2022, 06:35 PM

I like the way you think.

I’m looking at just making a “One Piece patch to weld in, so I won’t have to mess with the “Foam Seam Sealer”, and like you said, it’ll be covered by the Carpet anyways.
I just have to make sure that I get all the rust cut out and/or treated, so it doesn’t continue to decay.
I’ve been looking into the NHOU Underbody DIY kits to treat the insides of all my panels, which have, or will have surface rust.
According to what I’ve seen, their product is easy to apply and is very effective for rust treatment/preventative.

09-11-2022, 09:25 PM	#1
custom10nut Registered User Join Date: Apr 2015 Location: East Tn (In the heart of the Smoky Mtns) Posts: 1,846	Floor pan to kick panel Union? Today I really tore into my truck to find out what kind of patching I need to do the repair the rust. I already posted abou what I’m doing to fix my Rocker Panels, and will update that thread with pictures. My question is this: Where the Floorpan meets the bottom of the kick panels, How is this attached? Are they welded together, or tacked together and then sealed with seam sealer (Which it appears to be)? My plan is to cut out the old, fab patches, and Buttweld them in, but I need to know about securing the bottom part. Thanks is advance

09-12-2022, 12:10 AM	#2
jumpsoffrock Registered User Join Date: Apr 2014 Location: California Posts: 923	Re: Floor pan to kick panel Union? I was fiddling with that area a few months ago but never cut through it. From what I can tell the floor pan bents over ┌ on the drivers side. Then in my humble opinion the kick panel is bonded first with a layer of special seam sealer, maybe to handle high temps. Then it was pinch welded.

09-12-2022, 08:04 AM	#3
custom10nut Registered User Join Date: Apr 2015 Location: East Tn (In the heart of the Smoky Mtns) Posts: 1,846	Re: Floor pan to kick panel Union? I was thinking the same thing. Both sides of mine have small rust holes, about the size of a bic lighter. I plan on cutting all the rust out, fabricate a patch, and butt weld it in. Then I’ll seal it with a bead of body sealer. To me, it appears the truck came from the factory like that. I’d sure like to see a few more responses to confirm this.

09-12-2022, 08:25 AM	#4
Jason Banks Senior Member Join Date: Dec 1999 Location: TX Posts: 1,528	Re: Floor pan to kick panel Union? Yah, it's a layer sandwich down there. Edge of the floor pan is bent down, kickpanel comes down beside it and then you have the lower a-pillar on top of that. Spotwelds everywhere. The ones I have seen had that crummy foam seam sealer. I don't think it would be a crime to just weld it up on the inside though, since it won't be visible after the carpet is there.

09-12-2022, 06:35 PM	#5
custom10nut Registered User Join Date: Apr 2015 Location: East Tn (In the heart of the Smoky Mtns) Posts: 1,846	Re: Floor pan to kick panel Union? I like the way you think. I’m looking at just making a “One Piece patch to weld in, so I won’t have to mess with the “Foam Seam Sealer”, and like you said, it’ll be covered by the Carpet anyways. I just have to make sure that I get all the rust cut out and/or treated, so it doesn’t continue to decay. I’ve been looking into the NHOU Underbody DIY kits to treat the insides of all my panels, which have, or will have surface rust. According to what I’ve seen, their product is easy to apply and is very effective for rust treatment/preventative.



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