What size to drill holes for plug welding floor pans

[moparjohnny]

And what is the distance from each hole to hole? Thanks

 

[roadrunnerman]

I would say drill 3/8 of an inch and probably 2 inches apart.. Some people will go more and some less. Can you remember how many you took out of the old pan and uses that as a guide?

 

[RustyRatRod]

Really? Man, them workers used no rhyme or reason. I've seen about 2" like roadrunnerman said, and as little as 1" apart. Talk about a PITA to drill out.

 

[Pistol Pete]

5/16" for me.

 

[wannadrag]

5/16" for me.

X2

 

[Propwash]

X2

X3......



Roger's the Gung-ho one of the bunch.

 

[eric383]

At least 2" apart and closer won't hurt. I have a pneumatic puncher/flanger that made life a lot easier. Good luick.

 

[747mopar]

X4, I used weld threw primer for added insurance but found that it really made the welds crappy, I then just ran a drill in the hole to remove the primer from the spot weld prior to welding that seamed to work really well. I also made a set of vice grips (the ones that have a forked jaw) with a 1/4 thick copper plate on the bottom "it works sweet". I would clamp it to where the spot weld was in the center of the fork in the clamp then weld, I set the amps pretty high and start in the center of the hole, if set right the weld will flow right out into the hole leaving a fairly flat weld. That's just my two cents

 

[scotts74birds]

Good advice 747! Moparjohnny, have you thought about just using panel-adhesive, and just using a few zip-screws to hold and clamp it? I would consider this for a non-structural panel, like a floor-pan. That way you are attaching, AND sealing the seam as you do it. I work at the factory, and we use these adhesives everywhere! In "peel-tests" we have seen the metal fail before the adhesive let go. Just an option.

 

[wannadrag]

Floor pan is structure on these cars.