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06-21-2012 10:11 PM Inside Floor Channel
The welds were ground so the patch panels would fit. The panels were cut and bent to fit. The welds were ground enough to assure they were solid. These areas will be under the back seat, so I didn't think they needed to be perfect. Hopefully this is the last of the surprises.


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  [Entry #449]

06-17-2012 05:46 PM Cut, Weld, Grind, Repeat
Got a late start on Saturday. Went to an auction to try and buy a trailer. Went for more than a new one. And since it was more trailer than I originally wanted in the first place, it ended up going for about a grand more than the one I will buy from the dealer, saving 6 hours at the same time. Oh well, 6 hours of education. And I bought a pile of tools. LOL

Cut and welded in the three patch panels. The hole by the hump grew twice during the process. Ice pick assured it is all solid now.

In the first photo, you can see a hole to the left of the new patch. Apparently they "nailed" the carpet (mat) to the floor in several locations. A couple of them got patched on Saturday but I have to find a better way to do it. Going to see if I can back the hole up with copper somehow.

On the last photo, if you look to the left of the new patch in the bottom left corner you will see one horizontal and two vertical lack of fusion areas. I started back gouging and welding these Saturday as well. They are small. But I need to track them all down and fix them. Otherwise, I am sure they will develop into a crack sooner or later. This is what I intend to do during the coming week.


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  [Entry #448]

06-15-2012 09:27 PM Hole by the Hump
The bad flange was not unexpected when the floor was cut. What wasn't expected was the fact that the floor had more soft spots than originally thought so the hole had to be enlarged.

Everything is cut out. Next will be to fit and weld the patches.


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  [Entry #447]

06-15-2012 09:24 PM Holes
I really didn't want to start cutting tonight after work. I was afraid of what I would find. My rust bucket did not disappoint.

The left side was cleaned and then cut. The channel flange above the new hole was soft and buckled.

The right side wasn't as bad.

The left side of the channel was cut.

My choice is to cut out the whole channel and clean or replace all the metal. Or I can repair the worst and POR15 the rest. Going with option 2.


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  [Entry #446]

06-13-2012 09:10 PM Body Mount Holes / Broken Bolts
When removing the body, 2 of the 22 bolts broke. The inboard bolts on the center (behind the front seat) cross brace let loose rather than twisting out.

I drilled one of them out and cleaned the threads. One down, one to go.


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  [Entry #445]

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