Photos - rusty floors replaced

Damp carpet and rotting underfelt removed, this is what lay beneath. Many years of neglect and water leaks around the windscreen resulted in this mess.

A hard pull on the accelerator pedal and the whole assembly came away leaving a gaping hole in the floor.

This rust hole was covered by a "flexible white bog" when car was purchased. Buyer beware indeed!

Another view of the floor and bulkhead rust that had to be cut out.

This is what the bulkhead rust in the previous photo looked like from the outside after the white bog was removed.

Left hand floor rust, not as bad as the right hand floor but still required many hours to rectify.

More rust holes in the left floor, near the inner sill panel. The more you tapped the bigger the holes became.

Rust hole in the RH transmission tunnel about 30cm off the floor. Very unusual place to rust, probably caused by trapped dirt & moisture on the outside.

Reinforcement panel that supports front suspension torsion bar. Solution was to cut out and fabricate a new replacement from scratch.

Hammer and chisel was the neatest and safest way of removing the old floors. No sparks flying from grinding wheels or cutting torches and the finish was neat & tidy.

RH floor section first cut. More trimming required to prepare for replacement floor.

Yes that is the concrete garage floor you can see! Both front floors removed and more trimming still required.

RH floor and bulkhead panel removed. Area cleaned up ready for new panels.

Trimmed and cleaned up, awaiting new floor.

The new floors and RH bulkhead panel awaiting preparation and installation.

RH floor held in place with the aid of some fasteners and ready to be welded in place.

RH floor welded in place and awaiting grinding and clean up.

A MIG welder was used to Plug weld the panels in place. A strong and clean method that looks a bit like spot welding once finished correctly.

Both floors and the RH bulkhead panel completed and tidied up ready for seam sealing and painting.

Floors painted in rock hard POR15 anti corrosion paint then a primer ready for the white two pack.

Self adhesive sheets of sound proofing material were added to the floors and transmission tunnel area. More than original to cut noise and heat.

Finally, more coats of two pack Old English White were sprayed over the insulation material to complete the floors.

The satisfying result of many days of hard labour. Guaranteed to last for many years more than the original factory floors. Now waiting for the interior trim work to begin.

My Jaguar E-Type V12

Photo Gallery - Rusty floor replacement