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Old 12-09-2006, 11:51 PM
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Brian Martin,Freelance adviser
 
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Interesting approach at channeling an early Ford.

An interesting body channeling procedure.

There are more than one way to skin a cat. Thousands of early Fords have been channeled but I have never seen it done like my brother and his son are doing this 1946 Ford pickup.
It was made possible because he got another cab as a donor, this will limit the amount of people who could do it exactly as his is, but you could construct a new floor out of tubing and sheet metal and take advantage of his idea. The idea was his, but the work is mostly being done by his 21 year old son on this, his first rod. What they did was to remove the entire floor structure including “rockers” from the donor cab, along with the firewall.

Here’s how it goes; the original firewall was removed leaving an inch of it there A row of holes was drilled in this lip left from the firewall to plug weld the donor one in. The donor firewall was removed with a cut off disc right at the fold on the edge of it, right at the lip where it was spot welded to the cowl, leaving that lip still welded in.

So, what you have is a hole where the old firewall was that in an inch small all the way around the top and the sides. The donor firewall is complete and will fill the hole out to the sides and top of the cowl looking as original. It was removed on the sides of the cowl and toe boards by drilling out the spot welds taking the lip with it, as was the original one.
Photo 6

The original floor was very rusted with full replacement needed, along with the rockers. It was still solid enough to hold the cab together with the doors still fitting very well. So he decided to leave it in place until the new floor was welded in.

Photo 1

He removed the donor floor right at the jambs and the spot welds along the back of the cab and toe boards. The rear of the cab had a lip that was rolled under about an inch from the skin on the rear of the cab. When the floor is put into place six inches higher there will be a will be a gap from the rear of the cab skin to the floor. So, they welded a one inch square tube across the rear of the donor floor. Then after the donor floor was installed, cut the lower section from the back of the cab skin and plug welded it to the tube.

Photos 2 and 5 A the arrow you can see the tube on the inside and the original floor on the outside.

Photo 4 the red lines are the old and new locations of the toe boards welding point to the cowl side. A piece of sheet metal will be used to connect the old to the new location.

The green arrow shows where the firewall will meet up with the flange/lip of the old firewall.

The corners of the donor floor at the rockers were welded to the door jamb just as the old floor was.

The top six inches of the firewall was cut off and installed to check fit at the time of these photos. It fit right up to the floor at the bottom of the toe boards perfectly. An NOS tranny cover fits right in place!

Photo 3 at the arrow you can see the old floor thru the master cylinder access hole.

Photo 6 you can see at the arrow the lip from the old firewall.

Once the firewall and some support flanges are welded in place, the old rusty floor will be cut out and the cab set back on the frame six inches lower than it was before.

Let me clarify that the gray firewall and the bare metal floor are both from the donor cab.

The gray you see is epoxy primer over the sand blasted bare metal.

Neat huh?
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Old 12-09-2006, 11:51 PM
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Brian Martin,Freelance adviser
 
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And the last photo...
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Old 12-10-2006, 01:08 AM
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Cool trick Bet it saved alot of time.

You'd have to section up a floor for a passenger car because you couldn't get it through the door.

later, mikey
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Old 12-10-2006, 08:29 AM
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LOL. never thought of that. But how about cutting the firewall out, then "enlargeing" the transmission access hole a yard. You could go in from the front with the donor floor up on one side and snake it in then lay it down.

But again, not eveyone is going to have another floor. But making one from scratch right there before cutting the old one out sounds like a doer to me.

Brian
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Old 12-11-2006, 11:23 AM
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A good approach even if you don't use a donor cab or car body. This keeps the body structure intact and correct and allows you to do virtually the whole job before carefully cutting out the old rotten floor and finishing up the bottom side.
Thanks for the tip and photos.
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Old 12-12-2006, 10:44 AM
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This idea would also work on older cars and trucks without metal floors just subrails. Leave the subrails intact until a new set of subrails was installed at the correct height. Then remove the old cross rails and connect your new subrails to the old rails with sheet steel to cover the frame. Finally weld in your sheet metal floor.
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