How’s it going everyone, it’s been a while since I’ve been on the forums but just started a new project.
I picked up this 91 roller this week and have started my engine / trans swap. This thread is going to be a complete, picture full collection of the swap process.

Ive stripped the interior to inspect how the floors / roof are doing and found some expected but unexpected problem areas.

Passenger rear floor pan has been replaced before (not in an acceptable way imo) so I’m going to re-replace the passenger side front and rear panel. There’s a area right next to it, the kick panel area, that needs some help too.

Driver side is decent, besides the rear area. Not as bad as the passenger side, which is good.

The roof needs some repair on the passenger side near the B pillar, don’t know if I should have a full roof put on yet or what. There may be a 4-cage installed so I’d be able to do a complete weld of the tubing if the roof is removed and replaced.

Lastly, there’s a rear quarter lower area that needs to be replaced along with a small area of the wheel well. Not too worried about that one.

Ive already began looking for a possible cheap donor roof and quarter. I don’t know if I’m going to buy the floor pans aftermarket or look for decent cut out sections. If anyone tuning in has anything in need along the way please feel free to message me !

Also found out no one cut out a fuel pump access
panel. That was a definite plus for me !

 

I’m interested to see this play out and I hope you see it through to the end. I’ve put a couple L83’s into Jeeps but customer preference made the swap far harder than it had to be. Looking at the condition of your roller I suddenly feel very fortunate that I found my car because it is in fantastic shape in all those problem areas; nearly everywhere for that matter. But that you were concerned about a fuel pump access panel being cut after finding the rest of the floor in the condition it’s in seems a very odd thought to me.

 

I look forward to following this, Mine is a 1991 vert. Ls3/6L80 six speed. I think the 10 speed is similar in size to the 6L80 . I cut and raised the tunnel 1.5 inches. I finished my swap in 2013, it is for sale on this site. There are some pictures of how I cut the tunnel if you do a search . Good luck , you are braking new ground in the thirdgen community!

 

Rust doesnt look that bad compared to what I had to deal with on my 87 Iroc. Rust in the usual spots.

Before pics



After replacing front section floorpans, painted with POR15 and lined with "Home Depot Dynamat"

 

Looking to see how the 10 speed fits, should be good when done! Glad you have the means and motivation to clean up that rust, glad mine was good when I got it.

 

Is this still happening?