The driver's side floor pan was rusty and it needs to be replaced.

You can buy pre-made floor pans, but I had a sheet of steel the right size and thickness, so I decided to make my own.

I found three sources for pre-made floor pans. Good ones cost about $190 before shipping and tax.

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The floor is flat, but there a beads pressed into the floor to stiffen it. I could have simply used a flat piece but I thought the extra stiffness would be worthwhile, so I decided to try to add the beads myself.

I made a form the right size and shape from another piece of metal then used a ball-peen hammer to push the metal into the form.

The result is a little bumpy, but I'll try to work that out before I weld it in.

To prevent this from getting rusting again, I plan to use bed liner or something similar. This produce a durable, slightly bumpy finish that will stand up to abuse better than factory paint job (and hide any imperfections from my handmade beads).

I also have to make some repairs to the inside of the sill and the A pillar. I'll weld flat pieces in. The result will a be as good as new floor with a durable finish.

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