I have had some rusting issues with my floor pan (imagine that) and an area on the driver's side has rusted out around the floor pan plug hole. Is it OK if I just cover this completely when I patch the pan? It's not crucial to have this plug hole is it?

I never saw any use for it. Its hard to remove. I would remove it if there is rust at that point.

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TUATZ
[zekfrivolous.com]

I have had some rusting issues with my floor pan (imagine that) and an area on the driver's side has rusted out around the floor pan plug hole. Is it OK if I just cover this completely when I patch the pan? It's not crucial to have this plug hole is it?

"I you spill that LARGE COKE, your car will have to HOLD it in!" Norm K.

Lol...good point Norm. My floorpans weren't that bad, but besides the frame rails, the areas around these plugs is where a majority of the cancer was. I personally like having the plugs there, so I ground out the rust and did some patches. The frame rails are being replaced.

If you want to keep them, just make sure you put a good coating of POR 15 or some other product that is good at preventing rust, or a good paint job. That way, you still have the option to drain any fluids in the case that you do spill a 72 oz bladder buster big gulp on your floor.

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1973 240ZT - my money pit.
2006 Acura TSX - my DD.

Go ahead and cut out the rot and weld in a piece of metal. Don't worry about the holes. If you want drain holes in the floor then take a metal cutting hole saw and put a new hole in there. Usually those holes aren't neccessary though.
Z man of Washington

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1978 black pearl show car-retired, I bought it new
1983 zx turbo daily driver, modified, 3rd owner
1970 240 #23 being restored
1970 240 #638 driver
1973 240 roadster being built
about 70+ other z's & zx's
Recent inventory count was 92 all total
www.zspecialties.com
www.datsunstore.com
www.zman@zspecialties.com
1-800-518-5480

Does anyone have a good source for a *cheap* plug that fits the floor pan holes - especially the big ones? I have seen some on ebay but with shipping they end up being around $9 each! I could buy a lot of Big Gulps for that!

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Yellow - 71 240 '82 L28/P79 SU carbs, elect fuel pump, Holley regulator, 15K on stock rebuild, stock exh man, 2.5 exhaust, GM HEI, ZX alternator, Tokico Illuminas, Swastika wheels, Del Sol seats.

Blue - 73 240, '83 ZXT swap, ECCS, junkyard screamer. Miata seats!

If you're in Canada, go to Canadian Tire and into the "Help" aftermarket replacement parts n' bits area. They are there. I am going this morning for other things. I'll check what they are worth up here and let you know, in case you cannot find them there.

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I'm concerned with all the rampant sex and nudity on TV but all I can do is sit at home shaking my fist.

I've looked in the "Help" sections at the local chain parts stores, probably the equivalent of Canadian Tire. For your sake I hope Canadian Tire is better. I haven't yet found a plug for the 1 3/4 inch holes though.

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Yellow - 71 240 '82 L28/P79 SU carbs, elect fuel pump, Holley regulator, 15K on stock rebuild, stock exh man, 2.5 exhaust, GM HEI, ZX alternator, Tokico Illuminas, Swastika wheels, Del Sol seats.

Blue - 73 240, '83 ZXT swap, ECCS, junkyard screamer. Miata seats!

Would used plugs do or do they have to be new? Couldn't find much, but I may have some on the parts car if needed.

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I'm concerned with all the rampant sex and nudity on TV but all I can do is sit at home shaking my fist.

coat the entire floor board with fiber glass. Let the stinking metal rust out. The fiberglass will last longer than the car.

Fiberglass won't stick to rust, and it won't give you any structural strength either in this case. The floorpan is part of the framing of the vehicle.
ZMOW

fiberglass will be stronger than the thin floor board. As you know, there are some fiberglass bodied cars.

The idea is to coat the whole floor with glass, so hopefully there is some good metal there.

My floors feel super strong with glass.

1976, I've got the ones out of my old car in a ziplock if you end up needing them.
Just let me know. My e-mail is attached to my name.

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I'm concerned with all the rampant sex and nudity on TV but all I can do is sit at home shaking my fist.

Glass bodies cars use metal framing for strength and glass for skin. They don't use the glass for strength. They are engineered this way from the beginning. Covering rusty metal with glass only fools you. When your car starts to flex what do you think will happen to the glass then.......I'll give you a hint, crack kills. lol
There is a time and place for glass and it isn't for covering rusty floor pans. If you have a full frame car then it's not as big a deal covering rusty floor pans, but the glass won't stay there all that long if it's going to be on rotten or rusted metal. It won't adhere to it unless you completely kill every molecule of rust.
The floor pans are made out of 18 to 20 ga steel. That's way stronger than glass any day of the week.
ZMOW

Fiber glass just doesn't resist to flexion.
But, It have really proprietes for tention and compression.
The glue is the key most of the time, some epoxy glues are crazy.

DeClo, es'que tu est Francais?

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I'm concerned with all the rampant sex and nudity on TV but all I can do is sit at home shaking my fist.

Well, over 5 years later and my floors are still rock solid. I'll let you guys know when it cracks off, but don't hold your breath.

In my opinion, an old rusty Z isn't worth repairing in any other way. Like putting on a 2,000 dollar set of rims and tires on a 1000 dollar car, not worth it.