One final shot of the under seat panel showing how the seat bottom fits now.
A piece of panel was cut and located on the door. 1/8'' holes were drilled and Clecos installed. The panel was marked and trimmed to fit. Holes for the window switch and latch release were drilled.
One by one (sometimes two by two!) the Clecos were removed, the holes enlarged to 1/4'', and Auveco clips were installed.
The right panel was checked on the left door. It was close enough so it was used to trace out the panel for the left door, saving some time. The holes were drilled and Clecos installed. Trimming was started.
Now that the side panels have their base layer made, the location of the under the rear seat panel had to be established so the mounting holes could be drilled. The fabrication of the arm rests will also be dependent on how the under panel ''spreads'' the side panels.
The seat bottom was installed and measured. There was quite a bit to be removed from the stand-offs. I decided to not weld them since they are going to be so short. They were cut to length, the channel was cut back to clear the seat riser, and the tabs this created were flattened.
Moving the panel back in the car also placed it over a different floor profile. The ends needed the brake to be relocated. trimmed, and slightly folded over.
The panel received cuts at both ends to clear the frame and notches near the ''catches'' where the round rod connects to the frame.
Shims were used to represent the carpet and pad. The tabs were bent to locate the panel correctly. Self drilling/tapping screws were installed. The locations of the side holes were marked on the side panels.
The right panel was moved over to the left side to assure it was close to the correct size. The right panel was then placed on the remainder of the 4 x 8 sheet it was cut from, traced, and the left panel was cut out.
The right panel was trimmed at the front and around the window opening. Holes were located for what will eventually have Auveco clips passed through. For now, Clecos hold the panel tight against the metal panel. The holes for the seat belt mounts were located and drilled. The top spacer is overlapped by the window garnish, so I will have some modification work to do.
The first Cleco was installed on the left panel. The panel was then marked for trimming. Friday night or Saturday. Time will tell.
I also realized that two 4 x 8's will not be anywhere near enough material. The wife will hopefully pick up 3 more for me tomorrow.
I still haven't decided if I am going to use the wood from the old, original armrests or make new. I am leaning toward cutting up the 73 year old armrests and using the original wood as the starting point. Additionally, as if the resin on fleece for the speaker enclosures wasn't enough punishment, I think that is the process I am going to use for the armrest bases.
Some masking tape was attached to the floor and the window box to establish the leading edge of the armrest for future reference.
Masking paper was cut, taped together, taped to the interior panel, and cut to shape. The paper was then removed and attached to the 1/8'' PVC foam board. The leading edge was extended out by the width of the masking tape (1''). The rest of the perimeter was marked with a silver Sharpie.
A variable speed saber saw was used with a 24t metal blade to cut the panel. After some minor trimming, a single Cleco was installed to hold in place.