Floor Pan Install - 65 Dart Convertible

First step is to extract pan from the assembly.

I used a Harbor Freight spot weld cutter. That thing really cuts and it was very easy to drill clear through both layers of metal. Not a problem on this piece, but when removing the old pan from the car, it's very important to only cut one layer of metal. I tried hard to do this here as well as practice but I went clear through several times. The best technique I discovered was to get a screw driver wedged between the two layers of metal on either side of the spot weld if possible. This puts tension on the spot weld so that it will pop when you get through the first layer. Otherwise, it's impossible to know when to stop drilling. Carefull though, because they don't always pop.

Another challenge is to find all the spot welds. You have to clean off all the seam sealer and rust. Then a quick hit with some 120 grit sand paper brings them out nicely. Also getting them wet with some spit on your finger can help you see the outline.

You definitely need to center punch them with a nice sharp center punch. Otherwise the cutter will wander all over the place.

The last picture shows the pan free and clear of the old cross member and rockers.