How to Replace a VW Floorpan

Written by marlon trotsky
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How to Replace a VW Floorpan
Rust will likely eventually spread through your floorpan, forcing you to replace it. (yellow car image by JoLin from

A rusted out floorpan can doom your Volkswagen. The floorpan basically supports most of your car's structural and mechanical components, including the power train and suspension system. You should be able to handle the job of replacing the floorpan, although it helps to have some welding experience.

Skill level:
Moderately Easy

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Things you need

  • Rubber mallet
  • Chisel
  • Sawzall
  • Drill
  • Welder
  • Seam sealant
  • Grinder
  • Rust preventive
  • Undercoat

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  1. 1

    Start at the front passenger side, and take out the seats and floor carpet. Next, remove the battery, heater tubes and rear seat front support. When working on the driver's side pan you will also need to take out the pedal cluster by disconnecting the clutch cable.

  2. 2

    Cut the floorpan with a Sawzall from the inside of the car. Try to stay about ½ inch from the lip at the edge of both the front and rear supports and the tunnel, until you reach the heater channel where you should continue cutting from underneath the car until you clear the channel, then moving back into the car to finish cutting out the pan.

  3. 3

    Let the floorpan drop out by removing the pan bolts from the heater channel. Use a rubber mallet and chisel to remove what is left of the pan. Finally, go over the lip with a grinder to ensure a smooth surface..

  4. 4

    Drill the spot welds into the new pan in the spots where the rear chassis support is attached. Use the Sawzall to resize the new pan in the places where it attaches to the frame, usually taking out a rectangular piece from each corner.

  5. 5

    Get under the car and slide the pan onto the lip by bending up an inch of the pan's front edge 90 degrees. Once the pan is all the way in, bend the front edge back down.

  6. 6

    Replace the gasket around the edges of the new pan, bolting it into place, then weld the edges with a plug weld. Finally lay down a seam sealant all the way around. Once you're finished, spray the bottom of the pan with undercoat and the inside with a rust preventive.

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