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03-22-2008 07:49 PM More Prep of the Rocker Box
Once the floor cleared the brace, the box slid in. The outer panel was intentionally cut a little long. The distance from the tab to the cowl support was measured. Then the same measurement was transferred from the edge of the original rocker box to the green cut line shown in the first photo.
The second photo shows the fit after the cut was made on the green line. The A-pillar bottom was a little more rotten than I had first thought. A replacement piece for the soft area was fabbed up. The old piece is lying on the floor. Also note that some pie cuts were made so the "hump" could be moved to the center of the car, allowing the rocker panel to move out, lining up with the original better.



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  [Entry #107]

03-21-2008 01:32 PM Initial Fitting of the Rocker Box
A portion of the rocker behind the door needs to be removed in order to allow the rocker box to be inserted and then slid forward. These cuts don't have to be accurate, but I did want to leave as much structure as possible. In the end, I had to lengthen the cut by 2 more inches from what is shown in the first photo. The floor section needs to be removed as well. The inner panel has to have the lower section replaced, so I removed it with the floor.
The first fit shows that the floor on the inside of the "hump" is too low. It has to go on top of the floor brace, not under it. I attempted to reform it with a body hammer. I gave up in short order and cut a pie shaped piece from the inside side of the hump and will weld it once the final shape is determined.


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  [Entry #106]

03-21-2008 01:22 PM Prepping the Front of the Rocker Box
The rocker boxes from Chevs of the 40's (EMS boxes) are too long. I decided to do the driver's side a little different than I did the passenger side.
First, the outer rocker was cut back 3-1/4".
The inner panel was cut back 2-1/2".
Finally, a series of cuts were made on the floor. The rectangular shaped box was removed. A cut was made along the hashed marked section. The resulting 1" x 1" tab will be bent down. This welds to the body cowl mounting box. I wasn't sure if the hash marked area needed to be removed or not. When the unit was test fit the first time, it became obvious that it has to be cut out.


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  [Entry #105]

03-20-2008 08:10 PM Floor Brace Ends
The floor brace ends on the driver's side were in very good shape. From the condition of the rocker boxes, who would have guessed? Cleaned the rust off using the sandblaster. A quick coat of POR-15 and they are ready for some weld thru primer and the rocker box.


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  [Entry #104]

03-15-2008 07:37 PM Rocker Box
The replacement floor panel was positioned on top of the existing floor and tape was put down. This is to indicate the maximum cut. Fortunately, less will have to be cut out and the replacement panel will have to be trimmed.
After looking at the requirements of the floor and the rocker box, I decided it was best to replace the rocker box first and replace the floor panel once the rocker box is finished. The long continuous tape is the cut line for removing the box. A lot of cutting and chiseling got the box out.
The floor brace ends actually look better than the ones on the passenger side. This should clean up and go back together a lot quicker than the passenger side did.


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  [Entry #103]

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