Kick Panel installation

[pound41]

I have my b pillar done. I have the inner rocker and rest of floor pan patches screwed in place. My kick panel patch needs to go above the factory cowl/windshield to floor pan seam. Also my a pillar replacement cut is higher up than the kick panel cut. So here are my questions:
What did you guys use to cut out the rotted kick panel especially where the kick panel meets good floor?
Did you cut your kick panel and A pillars in the same place?
Does the kick panel sit down on the floor pan or is there a desired gap?
Is there any correct order to replacing most of the floor pan?
Does the inner rocker go 1st or does the kick panel?
Any help is appreciated!
Thanks

[lks dcvn]

Post up some pix and we can likely provide a bit more help...I am a visual person. I will try to answer what you have asked though.

What did you guys use to cut out the rotted kick panel especially where the kick panel meets good floor? I used a cut off wheel on a angle grinder to trim back my kick panel [it was the last thing I cut out] - if you have decent metal to work around then you might have your hands full though...if you have air tools then use the smallest wheel you can on a die grinder and see if you can finesse it out.

Did you cut your kick panel and A pillars in the same place? No for me on this one - to make it easier, I trimmed the kick panel lower than the A pillar patch so I could mock up the kick panel patch to the existing metal and then etch a line on it to have the best fitting patch [not sure if that makes sense or not].


Does the kick panel sit down on the floor pan or is there a desired gap? There are folds on both the kick panel patch and the exterior floor patch [or original piece] that allow them to seat pretty close together. A follow up with seam sealer to keep the debris and water out would also be on the list to complete it correctly.

Is there any correct order to replacing most of the floor pan? I can only tell you what I plan to do on mine. Since I have the outer floor extension piece which has the inner rocker and 4" of the floor already on it - I looked at several build threads to see the easier [can't say it will be the easiest yet] way to do it. My floor was solid with some minor pitting and surface rust so I chose to keep most of it and cut out the bad metal. I then did the fitting on the cab support and outer floor extension piece. With that mocked up I did the fitting for the kick panels and the outer floor using the folds on each piece that mates them together [I can get you pix if need be to show what the heck I am talking about]. Some have found it difficult to mate the drainage channels or the 'seat mounting floor bump' on the original floor to the patch panels and have cut around them to assure the floor looks normal after patching. If you check a few Blazer build threads you will see what I am talking about.

Does the inner rocker go 1st or does the kick panel? It will be a LOT easier to work from the middle out [to the outside] of the truck. I will be patching in this order:

1. Cab Support
2. Outer Floor Extension/Inner Rocker
3. Kick Panel
4. A Pillar Patch
5. Remainder of Cab Floor [only a few spots to fill after this is done]

Then I will move to the B pillar to tackle:

1. Create Patch panel for step up/floor
2. Bolt in Body/Step Supports
3. B Pillar Body reworking [bolts to body support]
4. B pillar Patch
5. Rear Quarter Front Patch

And then finish up with Outer Rocker fitment -

If you need pictures of anything - do not hesitate to ask - as this goes together I am taking plenty of pix - not sure if it is to make it easier for the other side or just to help others see what to look for when they go to buy a 69-72 Blazer.

I have reviewed the build pix of several key members to see how they did it - why not learn from others who have been there before. Here are a few to look over when you have time:

Big J's build - rust repair starts on page 2

vtblazer Blazer Tub Repairs

jaros44sr Rust Remdiation

rokcrln Rocker Replacement 101

Good Luck (and post up some pix of your progress)!