Making Our Own FACTORY Boot Floor using ONLY basic tools - Gemini Build - Part 6 

Mad effort it turned out great and glad to see the gem is back. I don’t mind at all watching the rust repairs and could motivate anyone to have a crack at it.

Top job persistence is Joy.

He'll yeah,that guy from make it custom is so talented.he makes difficult work look so simple.his channel is great.

Good stuff fellas. Thankyou

Try Dry ice on larger areas it works similar along with a Rubber mallet which will shatter it & then the screw driver. 👍😃

That's cool as guys - thanks! I've learnt a new idea :)

Dry ice! And a hammer! Done

Nice work, Michael, wanna make me one?😁My '80 TE wagon floor was a little bit less rusted, but my tank was like swiss cheese🤣 Managed to solder up the tank. Wire wheeled and rust convertered the boot floor, then fibre glassed it. Wish I knew about the freeze spray trick, I spent hours scraping that black crap off both front floors before fibre glassing them, and re-coated them with that horrible black tar goo again too😁 Fibre glass is much easier, keeps the factory drain channels, comes up looking factory, and will never rust again👍 I've also rubber paint coated the inside of the boot for noise suppression and hopefully moisture protection. The wagons suffered from condensation getting trapped between the tank and floor, hence why sedans didn't suffer as bad. I saw another comment about sedan boot floors possibly being the same as wagon floors, so might be worth looking into, but I guess you'll be nearly done by now.

Hey guys I teach how to make patch panels at home on my channel ( I call Bull) I use clear table protector plastic from Bunnings to make templates and show how to work the steel to get it to conform. I reckon if you had of shaped it with a ball pien hammer first then smoothed it with the air hammer it would have worked well. I don't reckon you should give up. Been with you guys since the start and still love your work 😊

Never give up, well done for sticking wit it! That will be a great floor, with minimal flaws and many broken saws and only a few sores.

Brilliant work mate .. I think a little underbody spray should hide the imperfections but well done 👍👍

Love to see the Gemini back - and the sheet metal work looks mint!

Would have been good to see the other Body work you did off camera, Maybe a second channel with more longer boring bits showing how you did it. Looks Mint

I’ve never done it before but I’ve seen it done a lot on RU-vid, as soon as I seen you put that sheet in the middle I knew it was too thick. Go 1.2 and a better tool this works a treat.

I wonder if it would have been easier using the cut out as a stamp in the press. I'm needing to do some replacement panels on my car so keen to try this

Dry ice works the best

Use 0.8 or 0.9mm cold rolled steel, use tig with ER 70 filler rod or stick welder with E4816 electrodes to weld the air chisel to end former knob

Brilliant!! Well done guys…

Come up a treat. Well done!!

Ive got a saab rear parcel shelf covering my boot floor in my tx coupe so my tools dont fall through the floor 😊

Great to see the Gem back!

Nothing consumes more time than dealing with the Dredded Tin Worm, can't wait for the engine reveal, as it's time yourself Micheal, to go fast.

Probably a bit late now but rare spares will have the floor on the shelf

Great effort lads, well done.

Awesome job

I think it would look mint with a false drop tank

I've never made a rust patch that didn't look like the factory piece.... ever. Oh, that's right you guys are mechanics... 😉

The idea is great lads next time use a smaller head and rock it side to side light welding if that makes sense

Gemini wagons share the same boot floors as sedans, so yeah they do make them haha.

Pretty sure you can buy that attachment from Sexyland

Take an Esky to Supa gas, fill it with dry ice pellets, then spread them across the sound deadener you want to remove, if you have a bigger area to do. Same effect as your can, but you can keep moving the pellets as you go. Plus you get to be a little childish and make a fog machine by putting them in water when you're done.

Yeh the gem Dam i need a panel too, since you have a template already?! 🤔😄

So you been watching Karl Fisher

Try clear plastic for your template next time, you can see through it!!

You needed to counter sink the bolts on the bottom, and put it on solid ground to take out the flex.

I used the freeze stuff on my whole car. Use half the amount you applied and I used the air chisel. So much faster.

Ha ha epic video Boy's!

Not sure why you put so many bolts through the panel. If it's clamped tight you don't need the bolts at all. Allowing it to pull in would make it ten times easier to mould. Panel presses in car factories allow the metal to pull into the shape they are trying to achieve. When you form a panel by hand with a stretching hammer and a recessed timber block or an anvil its not held tight, it moves around as you hammer it. The boards would have kept it flat and that's all that matters (considering it's a floorpan).

Why didnt you use steel plate instead of timber & heat it slightly. Wouldnt that be easier to work with?

FYI Dry ice if you want to do the sound deadening in the Fairlane. You can also make little dry ice bombs with an old plastic coke bottle, some water, and some left over dry ice pellets. (Obviously don't do this 😜)

Great work lads, any chance on renting out the template? I also have a gemini van floor to be replaced 😂

🍺👏👍🏻

Ur panel steel is abit thick buddy . 0.8 mm would work good

1.2 mm? You’re dreaming mateys. That good Isuzu steel is 0.9 , hence the pressed ribs.

Concept is sound and proven. Your sheet is just too thick. Keep up the good work it will get there. 👍🏼

Did your hands fall off after The air chisel

Another LS swap?

Your hand is not a hammer Michael, not good for you mate.

Gemini's back in the day rusted worse than Datsuns & that's the reason why we never bothered with Gemini's. Maybe a Barra turbo in the engine bay, just to annoy the purists?

Should have taken a photo first

1 mm would have been plenty, once you put the ribs in it would have given it its strength