Wanna see your guys pics of how you cut out your floor pans... worried about where the lca mounts and molds into the floor

 

Wow, that's some serious rust.

From the sounds of it, is the repair plan patch-work, rather than a whole
new aftermarket pan?

If the concern is how to cut out sheet metal, without cutting into the
unibody bracing, what about drilling small location holes from underneath?
Then you can establish cut lines inside.

Take pics & keep us posted on your progress.

 

Your drivers side is slightly better than mine. I'll be cutting it flush with the rocker and as far to the midline as I need to in order to find good weldable material.
The drill holes as guide lines is a good idea and is what I planned to do. Drill guide holes, plot it out on top, cut and then you can get the air chisel out and seperate the pan from the frame rail.
Lucky for me, the inner rocker needs rebuilding so I'll do that and then weld my hand formed patch to it... Few months away, I have to buy a garage first (maybe a house too).

 

I had a similar rust issue, I ended up making a patch versus buying an entire floor pan. I made sure that after I welded it in a seem sealed it and applied 3M undercoating afterwards.

 

What gauge of material did you use? I can get a sheet of 22ga pretty cheap. I'll hammer in some of the bead roll shape to give it some strength

 

The easiest way to go about removing it is to start with this:




http://www.northerntool.com/shop/too...a5axoCPMHw_wcB

The spot weld cutter will be your best friend. I used one of these when I replaced the floors in my convertible and it made the job much easier. Just drill all the round indentations out then cut above where the floor and subframe meet.
Also a donor car, if you can find one for cheap, helps a lot too.