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Patch for C3 floor pan / firewall

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Old Dec 27, 2019 | 01:30 PM
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From: Frederick MD
Default Patch for C3 floor pan / firewall

1968 C3 that has had the whole lower footwell destroyed on it. Basically the asshat that owned the car before removed all the lower heat shield and kick panels and something flew up into the bottom on the car smashing the lower footwell area on the drivers side. I’ve never done fiberglass work before but from what I’ve read it’s not terribly hard, just messy.

Given the damage / hole might be a better repair to just graft in a panel vs rebuilding. I’ve been attempting to locate patch pieces but haven’t been successful. Any leads on the panel in question. Pics of the damage.







Last edited by kossuth; Dec 27, 2019 at 02:30 PM.
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Old Dec 27, 2019 | 02:47 PM
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Helluva problem you've got there. Having taken my '80 down to bare birdcage with firewall removed, I feel your pain. I've made numerous fiberglass repairs to my firewall. You need to get at both sides of the cracks to properly 'V' them out and glass both sides. A super tough problem with engine/interior in place. Plus, there's going to be all kinds of dirt/grime/oily residue/factory sealer that will need to be removed and the area needing repair completely cleaned so the resin/glass will adhere properly. The floor I have much less knowledge of as mine is metal. But, there might be a replacement floor you could buy and cut pieces from to fit your missing areas. The same cleanliness issues will be there as with the firewall. Make sure you get the correct resin. Mine is SMC, yours may be different. A long time ago, I fixed a hole in my Jetski with fiberglass resin. Jetski's are SMC (sheet mold compound). The fiberglass resin didn't stick and the ski leaked like crazy.
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Old Dec 27, 2019 | 09:03 PM
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No leads on replacement panels, but I wouldn't hesitate to build the footwell from scratch. I was in a similar position as you, although I had no missing pieces. With some advice from DUB I fixed it myself and was pleased with the results. See mine, starting on post #48. https://www.corvetteforum.com/forums...69-vert-3.html

I would clean and prep the area, then use Vette Panel Adhesive to fix cracked areas. For the missing area, you could use cardboard to form those areas. Painters tape works to prevent resin from sticking to your form. Pre-cut some fiberglass fabric pieces to fit. You'd probably want to work on one section at a time as the resin has a limited window of time to get it on there. Once one section has hardened, move on to the next. Replace your missing shields so you don't wind up with the same problem again.

Alternately, pay a professional to fix it. Easier, but hurts your wallet!
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Old Dec 28, 2019 | 08:27 AM
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I have some good floor panels, but by the time (labor) I remove what u need, pack/ship, sell, you will be way ahead following the advice above repairing/building yourself.
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Old Dec 30, 2019 | 01:35 PM
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sheet metal for heating ducts is also a good mold material. wax or mold release compound on them so they do not become part of the floor.
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Old Dec 31, 2019 | 12:15 AM
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Use Plastic cutting boards the cheap thin flexible ones . Fiberglass can not stick to them so no need to learn how to use Mold Release. Duct Tape does stick to them so You can cut them to shape with scissors and then just tape them together. If You make a Mold for one side You can take it apart and turn it inside out and re tape it and You have the opposite Mold.
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Old Jan 1, 2020 | 08:29 AM
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Hi kossuth.

FWIW, I’ve seen stacks of Corvette bodies (all the vintage generations) at Paragon Reproductions in Swartz Creek Michigan. They might be able to help with a donor pan if George can’t help from TX.

Hope this helps...
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Old Jan 1, 2020 | 09:45 AM
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You don't need any new panels . I repaired one last year that was that bad. If you pm me I will give you my phone number and I will come take a look at it and show you how to fix it . I don't live too far from Fredrick Md. Thanks John
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