79cord
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  I have 2 4th gen Civic & a CRX that have had people ignore the factory jacking points & applying Trolley jacks to the front passenger floor, severely crushing their reinforcing rails & pushing up the floors around 2". Not looking forward to repairing that.. & open to suggestions.. 1. Cut hole in floor above & hammer rails down before welding shut floor again. 2. Cut off old rail & weld on handmade ones.. possibly not so easy given rails taper from 25-15mm deep. Possibly cut replacements from other cars. 3. Drill out old rail spot welds, remove & straighten rails to weld back on. |
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carefully remove and hammer straight or make new ones if that goes wrong
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91 golf g60, 89 golf 16v , 88 polo breadvan
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I've done the same sort of repairs to quite a few ae86s, option 3 is the only choice
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I can imagine 1 would have more potential to go wrong than 3, are you having to do it for registration purposes or is it just one of those things that need doing? My vote would be 3 if you can't ignore them  Edit sorry just read the floor was up 2"! What sort of muppet doesn't realise that's happening |
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with the rails off id imagine the floor will go back down with a lump of wood and mr hammer from inside
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91 golf g60, 89 golf 16v , 88 polo breadvan
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good boot will fix the floor with the stiffener removed  |
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79cord
Posted a lot
Posts: 2,607
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The fact the reinforcements run the full length of the floor with the frt & rear rails welder over.. err under the ends does make them a little daunting, & HATE welding underneath things.
I also looked at some Honda Concerto floor reinforcements I might be able to get which look similar though possibly thicker metal & separated into overlapping frt/rear pieces rather than 1-piece, later Civic look quite different.
Also considering only removing the worst area of the old reinf. & welding back together after.
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steveg
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Posts: 1,563
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Is it worth trying to pull the damage out before taking the rail off ? You will probably have to weld some sort of bracket onto the creased area to do it though.
If you have access to all the equipment needed to remove and replace the rail that would be the best way. Whatever you do though you will need to repaint a lot of it as anything there will already have cracked.
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If it's purely to get the floor back down then cut slots into the reinforcement sections at maybe 6" spacings then bash the floor back down and slots will open up. Weld the slots back up.
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wont pull that down without some specialist gear
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91 golf g60, 89 golf 16v , 88 polo breadvan
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Just to make life easier, I would combine #1 and #3.
Since you are willing to be welding in a new chunk of floor, rather than work with the chewed up remains of the floor after removing the spot welds, I would run the sawzall along the outside of the frame rail and remove the frame-rail, floor and attaching spot welds all in one piece..
Grind off the remains of the floor on the bench.
Use a press to re-shape the rail. Don't beat it cause that stretches the metal.
Butt weld new floor section in place
Offer up the newly reformed frame section and puddle weld back in.
Bit of rockguard paint to finish it all off and it should look like new.
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Nov 25, 2016 11:55:53 GMT
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I'd agree, but I think I'd reverse the two welding stages, not least because it's easier to weld "down" than "up". Weld the straightened frame section back in place from above, then replace the floor over it, all welding from above.
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79cord
Posted a lot
Posts: 2,607
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Nov 25, 2016 14:54:27 GMT
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Definitely prefer welding from above where possible.
Floor shape convoluted by design so wouldn't want to be welding patches into that if avoidable.
Looking at the way Concerto separated the rail into overlapping pieces I will probably just replace the worst areas.
If I can get/make replacement reinf. section, will drill spot welds to identify & grind off bad areas of old rails to avoid mangling floor, straighten floor & plug weld through drilled holes to new rail.
Still a few plug welds required from below at overlap of new rail section to old & where damaged floor rail does into front rails.
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Last Edit: Nov 25, 2016 14:59:37 GMT by 79cord
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