VW Beetle Floor pan install

Step by step tutorial for removing and installing new floor pan halves in your Volkswagen Beetle. The process is demonstrated on a 1965 Beetle floor pan, but is also applicable to other years.
Beetle floor pan dimensions diagram:
www.thesamba.com/vw/gallery/p...

[@JMC8415]

This video is AMAZINGLY detailed and just what I needed to watch to give me the confidence to take this myself!

[@dsteck5888]

One of the best videos out there on pan resto

[@okolemahu]

Callahan, your work ethic and craftsmanship is second to none and definitely an endangered species. Keep up the excellent work.

[@glenb9]

Fantastic video Callahan. I appreciate how well you explain your approach and the actual steps to complete.

[@carkingspot3973]

Probably the best video on how-to replace floor pans. Very thorough and to the point. Thank you. Now… all I need to do is figure out how I can do all of this in my 1 car garage. 😅

[@user-gv3bt5mi3o]

wish i had a garage

[@jeremyshearer]

I don’t have a garage lol

[@RedSun-Cinema]

Always, always, always drill the welds and use an impact chisel to remove the leftover metal after cutting off the floor pans. This is VW Bug 101 people. Doing it the way he's doing it will result in premature deterioration of the new spot welds and also lead to leaking from the floor board.

[@daleeizenga9411]

Love these videos. Instructive with tips from experience. I'm working with a friend to do a better restoration than what was previously done on my beetle and these are a big help and encouragement. I keep needing to remember that when someone last worked on my 66 it was probably worth half what it is now. The job they did made sense for their money and skills. Keep the videos coming!

[@howardkeil1526]

Thanks for the video nice thorough 53:51 instruction and attention to detail. That said don't repeat what you said in different ways every time you say it. And just a tip you don't need to say pan half every time. If you just say pan we will know what you are talking about.

[@secoff1]

I've done this a few times. Exactly the way you did it. Cleaning up previous work is a real drag. I swear VWs are among the hackiest of old cars. Everyone and their brother butchered these things back in the day. I've used sheet metal screws to act as a extra set of hands to hols to the pan while welding. I then unscrew them and plug weld the holes. It's good to see you taking the time to do it right. Hope your friend appreciates the work.

[@autoknight747]

Years ago I sold a Beetle because it needed these. I’m a technician but have never learned to weld. I’d want you working on any Beetle I owned. Outstanding attention to detail. Very satisfying to watch! Subscribed.

[@philcappellini2820]

Rotisserie? Who needs a rotisserie? Use your barstools 😃!! I am glad your back doing VW stuff again. Great video!! Thanks.

[@Mr572u]

I think you did a great job and tripled the value of that chassis!👍

[@bbrown_sc]

That was a great video Callahan. Very thorough. Best I've seen. Thanks for the content. I'm tying to decide if I should replace the pans on a 67. They are in pretty good shape. Just a couple of dime size holes. Knowing now what it take to replace the pans with your video, I might do that.

[@albertperez7564]

Thank you have 65 sunroof ready to start

[@JB-vr5df]

Very descriptive and detailed videos just in time for my body off resto. This has helped me immensely. Please keep the videos coming.

[@thomasduncan8289]

Man thank you so much for making this video! About to start my floor pans on my 66'

[@haskyb9184]

Really enjoying your uploads on David’s car, dude. Super informative and interesting. You’re a great person to learn from. Enjoying watching from across the pond in the UK

[@chrismitchell1980]

Nice video. Very inspiring. My son and I are about to jump into the same project with our 1971 SB (Plus a lil pressure from Wifey/Momma). Have to do some frame head work (napoleon Cap and bottom plate) then floor pans, heater channels and so on and so on and so onnnnn...... I'll be watching the rest of these videos FOR SURE. Thanks for the inspiration

[@pauledge9851]

Sensational Floor Pan video Callaghan.... Just got on to your vids and they are awesome. Thanks for the detail and thorough explanations.. awesome stuff. I'm in the process of body removal on my 69 Bug, ready for new WW pans too

[@mikaelassef2987]

Thanks for the video, I had the exact same issue with WW pans and the tunnel lip!

[@careyjohnson1784]

I really appreciate the video helps me out more than you know

[@juniorclassicvwbugs924]

Great tutorial, nicely done

[@angelsoterojr]

Nice Finally someone who gave all the details I needed to know.🤙🤙🤙 Thx

[@joedenton7023]

Very well made video, keep up the excellent work! I’m just getting into this and need all the help I can get!

[@vwcoco]

Poor crumby previous repairs but atleast it kept the beetle on the road and saved from the crusher 👍

[@mattevans9193]

Excellent instruction. Thank you

[@royzkees]

Thanks! Friggen awesome DIY video.

[@EYE_SPIDER]

Very cool, great video!

[@KG72]

Nice engine sound on that type 34 KG

[@jeffrey-deitch]

Excellent content & instruction!

[@RickPiper1]

Great teaching man!

[@MrGunPilot]

Great job! thanks.

[@annies_vw]

phew, I am glad that's one repair I don't think I'll have to do. All the other repairs, yup. But I think I'll get off the hook for this one. Nice job, I would've approached it the same way.

[@mattlee007]

you explain things really nicely ..but it would be good to see a little demo. please!! love your work though ... especially seeing i'm a diy guy in my garage, you help me believe i can do this... so cheers

[@LewmanArmsMan]

So that’s where my 64 T34 ended up..🤙

[@georgeezzell4474]

Great job.

[@anthonyconti9755]

Nice job, GOOD VIDEO

[@jessejames4284]

Very through. I enjoyed watching. I subscribed. .

[@kjeldlarsen912]

Thanks for the video

[@robertlong6118]

Awesome! Thanks

[@bartgoins1782]

I just found your channel, and really enjoyed this video. I do have to say, I watch videos while wearing a headset, and your music is a bit loud. Other than that, great video.

[@jamesfrench7710]

Nice. Job

[@reginaldash5067]

hay very good class on install thank you so much

[@davetipton5756]

This is for algorithms

[@roberthendricks9078]

That was a great video, thanks for taking your time to set up camera and being very thorough. How much do you charge for replacing floor pans?

[@ineverhadthemoney7857]

use a air chisel ,fast and easy work

[@vayabroder729]

Great quality pans. Question: could panel adhesive be used either partially with welds too? I’ve seen Mike Fn in his channel using panel adhesive for Bus cargo floors. I’ve always wondered if that could work on Bugs.

[@michaelheiser861]

pull the tunnel out a bit

[@user-gv3bt5mi3o]

Hello sir like your videos and I've subscribed thinking of buying a beetle one of the last 300 made in Germany its a silver one but it needs floor pans and heater channel im new to it .

[@EngineeredToDesign]

Great tips in this video! Does this all apply for a McPherson strut type beetle to?

[@callahansgarage]

Yes, the floor pan procedure is the same.

[@d3w4yn3]

PIZZA BOX FOR THE WIN!!! Okay, joking aside (although I wasn't joking!) you do very good work!!! Your detail is really on-point. I thought I knew a lot about the VW Beetle, but you've taught me much here, and that's hard, because I'm old (and a slow learner). So this all begs to ask..... how long is your backlog for work? I have a 71 convertible (super beetle) that I might need floor pan work on, but I won't know until February or so of 2024. Let me know?

[@maldonpayne]

Question: When you welded the outrigger to the torsion tube bracket from the bottom, did you use a stitch weld?

[@kwhitney6238]

8mm hole for welding

[@kwhitney6238]

Just got a 74 standard beetle. So I'm new any pointers on where to start for my restoration? Also I can't get the trunk open any information on that would be awesome

[@ORTLIEBRC]

Have you ever used panel bond for the floor pans?

[@donniewayne6931]

Good video good work as much as I like the idea of Volkswagen I would not fit in one. The only question I have is where the tunnel was nudged warped quarter inch from the edge of the floor panel I would have done good side first then wedge out the tunnel with wood blocks or with long wood clamps with the ends of the floor pan clamp down in four places. Is there a law that says you shall not mess with the tunnel?

[@callahansgarage]

The tunnel was not warped, the inside edge of the floor pan was cut too short from the manufacturer. The tunnel is a totally enclosed unit, think of it like a boxed frame rail, you're not going to wedge it or move it into place without extensive metal work.

[@HedigardiCardoso]

Boa noite kallaran meu nome é Hedigardi tudo Bem Espero que sim tenho um Fusca 1961 não tenho certeza mas está 2 cm de diferença entre os eixos como faço pra Alinhar Desde já Agradeço Felicidades feliz Ano Novo Com muita Paz E Saúde

[@richgorsuch7331]

My biggest fear with replacing pan halves is that the pan holes don't line up perfect with the body holes when the body goes back on.

[@chrismitchell1980]

P.S. The Cadillac's are FIERCE!!!!!!!!!

[@bobbysharp]

Callahan, what did you spray on the tunnel and let dry overnight. You know me btw, owner of Geek ('64 Sunroof).

[@callahansgarage]

Weld through primer. It doesn’t require that dry time, it was just the last thing I did that day.

[@curtissimpson7856]

Are the 20 guage pans to thin not worried bout original just wanting to have a solid floor without holes. Can get a set of 20 guage for $300

[@callahansgarage]

I have used them before and they are fine, but I definitely prefer the oem thickness pan halves. They feel much more substantial

[@DebbieHernandez-ik8zz]

Can this be done properly with the body still on the chassis?

[@callahansgarage]

Technically yes, but I would never advise doing pan halves with the body on. It makes everything more difficult and hard to access.

[@johncollins5552]

Do you not remove all paint from the areas to be welded?

[@callahansgarage]

yes, i dont remember if i specifically showed this in the video but every weld joint is ground clean on the base flange and the new pan half.

[@BigBuick]

roughly how many hours did floorpan removal + install take?

[@callahansgarage]

It’s about around 8-10 hours. I’ve done it faster if everything goes smoothly.

[@Earlydoors272]

No measurements needed before removing the old pans? Are the replacement pans good enough to just weld in without checking width etc?

[@callahansgarage]

This is discussed in the mock up phase of the video before the new pan halves are welded in.

[@Earlydoors272]

@@callahansgarage premature comment disorder. I commented after watching you cut out the old pans. I've seen other videos where they do measure first. But as long as it works 👍

[@ancnfamily]

are you using mig of flux

[@callahansgarage]

Mig

[@charliewhitlock6210]

Man some people just have no idea how to do a job the right who would do that kinda shitty work if you don't know how to do the job then don't try to do it with out doing some research on doing the job!! Enough said 😐

[@richardcattafi1327]

dude.....your killing me with all the ads !!!!!!!!!!!!