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Old 07-28-2020, 11:47 PM   #1
cgg17
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1995 SW2
Default 95 Sl2 Floor Pan Repair and Replace

I separated the donor pan from the frame first to see how to do it. It was quite simple actually, just drill the welds and pull it up.




The floor pan needed to be removed on my 95, so I drilled all the spot welds and ripped it out. Kind of got mangled but it was bad anyway. Underneath were some nasty surprises.









I also removed the floor cross member as well as trailing arm mount point. I had to cut along the end of the mount, but the rest was just drill and remove.






Here is the old crossmember compared to the new donor piece.



...
1994 Sl2 5spd First Car, Stock: 56,576 (Totaled 1/10/2018)
1995 Sl2 5spd: Retired Daily, Not Stock: 192,000
1998 Sl2 5spd: Family Car, Stock :135,000
1995 SW2 4spd: Daily, Stock: 91,000
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Old 07-28-2020, 11:49 PM   #2
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Default Re: 95 Sl2 Floor Pan Repair and Replace

Installed the new cross member and trailing arm mount by filling in the spot welds and then backing the rail side with a piece of steel and filling in the rest of the small gap with normal weld. I did multiple passes to really build it up. It is not pretty but it will hold.




I sanded down and painted both side rails as well as the open rocker area before installing the cross member. The seams all got coated with weld through primer for rust protection.





I had to graft the top ¼ of the old pan to the bottom ¾ of the new pan. The new pan did not come with the top, but the old one was good enough to work with. I patched three small holes and then welded the two together. There is about 2-3” of overlapping steel, welded on each seam.





Here’s the pan being installed. It has some dings and dents from working with it, and I had to hammer a few spots in to get it to line up nicely with the supports underneath. It is not the nicest looking floor pan but it is solid and has zero rust on it. Nobody will see it so I shouldn’t worry about looks at this point. I am glad to have a floor back in, I cannot wait until I actually have an interior again.



...
1994 Sl2 5spd First Car, Stock: 56,576 (Totaled 1/10/2018)
1995 Sl2 5spd: Retired Daily, Not Stock: 192,000
1998 Sl2 5spd: Family Car, Stock :135,000
1995 SW2 4spd: Daily, Stock: 91,000
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Old 07-29-2020, 12:24 AM   #3
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Default Re: 95 Sl2 Floor Pan Repair and Replace

It's almost like you are serious about this!
...
Bryan Cotton
'99 SL2, 5SP bought new
Rebuilt at 204,067 September 2017
Engine, subframe, diff pin mod, brake lines, headliner, alternator, and so on!
'98 SC2, 5SP bought 2018
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Old 07-29-2020, 08:14 AM   #4
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Default Re: 95 Sl2 Floor Pan Repair and Replace

Looks like excellent work.

I sense an almost missed opportunity to add a FP access hole in the back. I don't know what other manufacturer's did but all Subaru did was stud-certs in the floor around an oval hole with a rubbery seal on the lid to keep vibrations down and exhaust smoke out.
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Old 07-29-2020, 09:16 AM   #5
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Default Re: 95 Sl2 Floor Pan Repair and Replace

impressive work for sure!

I'd second adding a fuel pump access. I'd hit the local salvage yard and find one that would work and cut it out.

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Old 07-29-2020, 09:35 PM   #6
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Default Re: 95 Sl2 Floor Pan Repair and Replace

I thought about it, but I think I am just going to leave it be. The car needs to go back together, I am longing for a full interior once again. Also I do not mind dropping the tank, as long as the lines aren't still pressurized (long story).
...
1994 Sl2 5spd First Car, Stock: 56,576 (Totaled 1/10/2018)
1995 Sl2 5spd: Retired Daily, Not Stock: 192,000
1998 Sl2 5spd: Family Car, Stock :135,000
1995 SW2 4spd: Daily, Stock: 91,000
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Old 07-30-2020, 12:08 AM   #7
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Default Re: 95 Sl2 Floor Pan Repair and Replace

Quote:
Originally Posted by cgg17 View Post
I thought about it, but I think I am just going to leave it be. The car needs to go back together, I am longing for a full interior once again. Also I do not mind dropping the tank, as long as the lines aren't still pressurized (long story).
Perfect is the enemy of good enough. Nice job.
...
Bryan Cotton
'99 SL2, 5SP bought new
Rebuilt at 204,067 September 2017
Engine, subframe, diff pin mod, brake lines, headliner, alternator, and so on!
'98 SC2, 5SP bought 2018
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Old 07-30-2020, 01:22 AM   #8
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Default Re: 95 Sl2 Floor Pan Repair and Replace

Awesome job and great pics. I'm going to have this done to my Saturn eventually. NYS rotted most of the undercarriage
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Old 07-31-2020, 05:49 PM   #9
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Question Re: 95 Sl2 Floor Pan Repair and Replace

What was wrong with the donor body?

It seems it would have been simpler just to fix that car and drive it...
...
Currently owned
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99 SC2 A
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Old 07-31-2020, 06:15 PM   #10
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Default Re: 95 Sl2 Floor Pan Repair and Replace

Quote:
Originally Posted by onlinebiker View Post
What was wrong with the donor body?

It seems it would have been simpler just to fix that car and drive it...
The donor car was smacked pretty hard in the front end, I got it off of a saturn friend from facebook forums
...
1994 Sl2 5spd First Car, Stock: 56,576 (Totaled 1/10/2018)
1995 Sl2 5spd: Retired Daily, Not Stock: 192,000
1998 Sl2 5spd: Family Car, Stock :135,000
1995 SW2 4spd: Daily, Stock: 91,000
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