Repairing crushed rails / dented floor
#1
Full Member
Thread Starter
Repairing crushed rails / dented floor
Repairing crushed frame rails and dented floor pan.
So i've reached the part of my restoration where its time to try and straighten out the floor pan. Evidently someone has in the past jacked it up using the rails underneath leading to crushed rails and a floor pan.
The sills I can bend back and tap into place with a sheet metal hammer, the rails themselves I think I can probably get close enough with a slide hammer and various attachments. Its the floor pan that's making me scratch my head.
As you can see by the below photos, the whole rail itself has been pushed upwards into the floor pan.
I've had a half hearted attempt to knock them out with a block of wood and a lump hammer from the inside, but its not done anything, anyone have any thoughts on how to go about it.
I realise that I could drill out all the spot welds and take off the rails which would then make it easy to beat the floorpan flat, but I want to avoid that if at all possible.
Some pics, they aren't the worse I've seen but not the best either. Weirdly the UK car seem to get some side reinforcement rails that I've not seen any pics of on your US cars.
So i've reached the part of my restoration where its time to try and straighten out the floor pan. Evidently someone has in the past jacked it up using the rails underneath leading to crushed rails and a floor pan.
The sills I can bend back and tap into place with a sheet metal hammer, the rails themselves I think I can probably get close enough with a slide hammer and various attachments. Its the floor pan that's making me scratch my head.
As you can see by the below photos, the whole rail itself has been pushed upwards into the floor pan.
I've had a half hearted attempt to knock them out with a block of wood and a lump hammer from the inside, but its not done anything, anyone have any thoughts on how to go about it.
I realise that I could drill out all the spot welds and take off the rails which would then make it easy to beat the floorpan flat, but I want to avoid that if at all possible.
Some pics, they aren't the worse I've seen but not the best either. Weirdly the UK car seem to get some side reinforcement rails that I've not seen any pics of on your US cars.
#2
(Terraplane)
Those are the worst I've seen.
Get that air chisel sharpened and try something like this.
https://www.rx7club.com/2nd-generati...rails-1088241/
Get that air chisel sharpened and try something like this.
https://www.rx7club.com/2nd-generati...rails-1088241/
#3
Full Member
Thread Starter
I've seen way worse on MX5s. But in fairness they're made of butter.
I have some frame rails, but in order to make them fit I'll have to cut a slot out of one side of them, you can see down at the bottom of the pics where the UK cars have a lateral rail to reinforce the chassis. Unfortunately I think with that cut out they won't have the rigidity to pull the floor flat again.
Not sure why I'd need an air chisel as I want to avoid cutting the rails out if possible, if I do decide to cut them out then I'd probably take the nuclear option which would be this:
https://www.norotors.com/index.php?topic=17423.0
I have some frame rails, but in order to make them fit I'll have to cut a slot out of one side of them, you can see down at the bottom of the pics where the UK cars have a lateral rail to reinforce the chassis. Unfortunately I think with that cut out they won't have the rigidity to pull the floor flat again.
Not sure why I'd need an air chisel as I want to avoid cutting the rails out if possible, if I do decide to cut them out then I'd probably take the nuclear option which would be this:
https://www.norotors.com/index.php?topic=17423.0
#5
Full Member
Thread Starter
I am edging towards this now, I feel like I'm only asking people because I know what I have to do and am just looking for a reason not to do it!
#7
Full Member
Thread Starter
Yes I've noticed that about most my cars.
I've stripped out the dash and carpet to get at it and I'm now certain its a rail off job, I've no idea how whoever did this managed it.
The damage to the sound damping material was done by me while attempting to beat it flat with a big block of wood and an even bigger hammer. To no avail.
I've stripped out the dash and carpet to get at it and I'm now certain its a rail off job, I've no idea how whoever did this managed it.
The damage to the sound damping material was done by me while attempting to beat it flat with a big block of wood and an even bigger hammer. To no avail.
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#12
Full Member
Thread Starter
I had to cut out the bottoms of the rails to get rid of some rigidity but I've managed to get it about right. With the frames gone, excessive hammering and big wooden block did the trick.
Not the easiest to see but you can see how both sides of the car now match.
Now I just need to decide how to fix the frame, either remove it entirely and make up a new piece, or possible go through floor box section style.
Oh and go back around with a hammer and dolly to straighten out the floor pan stiffening grooves.
Last edited by theDevilX; 10-17-18 at 06:39 AM.
#13
Senior Member
iTrader: (1)
Nice, but you should realy get a spot weld drill, that way you could remove the rail, straighten it out and reweld it.
I use one of theese, and it's amazing.
https://www.ebay.com/itm/Spotweld-Cu...wNN:rk:13:pf:0
And i just bought weld thru primer for my project, so i can go full Binky..
I use one of theese, and it's amazing.
https://www.ebay.com/itm/Spotweld-Cu...wNN:rk:13:pf:0
And i just bought weld thru primer for my project, so i can go full Binky..
#14
Full Member
Thread Starter
Nice, but you should realy get a spot weld drill, that way you could remove the rail, straighten it out and reweld it.
I use one of theese, and it's amazing.
https://www.ebay.com/itm/Spotweld-Cu...wNN:rk:13:pf:0
And i just bought weld thru primer for my project, so i can go full Binky..
I use one of theese, and it's amazing.
https://www.ebay.com/itm/Spotweld-Cu...wNN:rk:13:pf:0
And i just bought weld thru primer for my project, so i can go full Binky..
That spot weld drill looks nice, but no way am I waiting for shipment from America to the UK. I'll get something local if I do.
#17
Rotary Enthusiast
iTrader: (8)
Those are the worst I've seen.
Get that air chisel sharpened and try something like this.
https://www.rx7club.com/2nd-generati...rails-1088241/
Get that air chisel sharpened and try something like this.
https://www.rx7club.com/2nd-generati...rails-1088241/
You dont want to see our 1st gen E Production chassis then. :P
#18
Junior Member
Those are the worst I've seen.
Get that air chisel sharpened and try something like this.
https://www.rx7club.com/2nd-generati...rails-1088241/
Get that air chisel sharpened and try something like this.
https://www.rx7club.com/2nd-generati...rails-1088241/
#19
(Terraplane)
I will no longer bring my FC into tire shops. They have crushed my rails every time. It's a 30 year old car and can't afford more damage.
I thought about refusing to have them put it on a lift and only jack the sub frame but I can't relie on that unless I supervising the process.
I am resolved to removing tire/wheels and bringing them to them.
I thought about refusing to have them put it on a lift and only jack the sub frame but I can't relie on that unless I supervising the process.
I am resolved to removing tire/wheels and bringing them to them.
Last edited by TRRAPLN; 10-24-18 at 11:39 AM. Reason: sp
#21
Ban Peak
iTrader: (49)
Why not just drill an anchor into the floor concrete floor, put an eye-bolt with a steel plate on the top through the floor of the car, attach the two with chain, and then lift the car by the jacking points with a couple jacks or a lift?
That should pull the floor back down and it will be easier to weld a few bolt holes up from the topside of the floor rather than weld upside down.
That should pull the floor back down and it will be easier to weld a few bolt holes up from the topside of the floor rather than weld upside down.
#22
Full Member
Thread Starter
Thanks for all the assistance, but as per my earlier post I've got the floor as flat as it was from factory. I'm just prepping up to weld in new rails.
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