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Part of rear floor

Part of rear floor

At its front edge, the new floor should be plug welded round the edge of the spare wheel well. It should also be welded edge-to-edge between the spare wheel well and the wheel housings.


1. Mount the car on an aligning bench and realign to the correct measurements if necessary.

2. Remove the rear bumper abutment, see Rear bumper abutment.

3. Drill out the spot welds securing the floor pan to the frame members.

4. Roughly cut the rear floor and lift it out.

5. Drill out the spot welds securing the sides of the floor to the wheel housings and remove any remaining edges of sheet metal.

6. Realign any deformed metalwork.

7. Use a grinder to clean the areas on the body that are to be welded.

8. Cut the new floor so that it will overlap the joint by about three centimetres.

9. Punch holes for plug-welding where possible. Remaining holes are drilled using a 6 mm drill bit.

10. Position the floor pan and fix it with a few welding clamps.

11. Cut through the new and old floors between the spare wheel well and the wheel housing simultaneously so that the joints can be welded edge-to-edge.


12. Remove the floor and use a grinder to clean the areas that are to be welded.

13. Apply welding primer to the surfaces which are to be welded. Use Teroson Zinkspray.

14. Position the floor in the car and fix it with welding clamps.

15. Plug-weld the new floor along the edge towards the spare tire well.


16. Weld the joints between the spare wheel well and the wheel housings.

17. Spot weld the edges of the new floor.


18. Plug-weld the floor to the frame member and a new reinforcement on the right-hand side.


19. Fit the rear bumper abutment, see Rear bumper abutment.

20. Wash off surplus welding primer. Welding primer makes for poorer adhesion of paint, filler and sealant.

21. Apply primer to all surfaces that have been ground clean. Use Standox 1K Füllprimer.

22. Seal joints and metal folds with putty. Use Terostat 1K-PUR.

23. Apply PVC substitute to the underside of the floor. Use Terostat 9320.

24. Apply anti-corrosion agent to the frame members going towards the new floor. Use Terotex HV 400 T 129 or Mercasol 3.