To view the beginning of this project see 1974 Datsun 260Z LS-1
After a complete disassembly the Z uni-body was carefully media blasted especially in confined areas of factory overlapping metal. As is typical with any uni-body design, the passage of time and the invasive power of moisture, can cause serious levels of metal degradation.
In picture #1 and #2 the floor pans clearly are prime candidates for replacement. Some portions of the floor pans were so rusted that the metal flaked-off under minimal pressure. Fortunately, the transmission tunnel was in very good condition which will be helpful when modifying it for the LS-1 engine and new transmission.
Before the new floor pans are fabricated, custom made frame support bars were designed and installed to reinforce the existing frame from twisting under acceleration from the potent LS-1 torque levels. Pictures #3 and #4 illustrate the placement of the frame support bars running parallel under each side of where the new floor pans will be installed.
With the supports in place our metal shop crew measured, designed and fabricated floor pans with a heavier grade of steel than those available from after market panel manufacturers. When a project has multiple phases in the metal shop we will consult with our client with options that are OEM designed versus those that take it to a more serious level of restoration; hand skilled custom fabrication. Picture #5 displays the custom made passenger side panel ready for installation.
The combination of thicker floor pans and frame supports adds a stronger dimension to the structural integrity of the Z uni-body. In picture #6 driver side and picture #7 passenger side, the metal work is near completion.