I used an angle copying tool to mark the main bend lines on a flat piece of steel. Measurements were pulled from the original and laid out on the piece.
After braking the sides and bottom, the shrinker and stretcher were used to shape the piece. The original part was placed on cardboard and the shape was traced so the new piece could be verified.
Then the tornado sirens started going off, so I called it a night and closed up the garage. Hopefully I can get the brace finished tomorrow night.
Given the choice between grinding welds and root canal surgery, I would have to think about it for a while before deciding.
Ground the butt welds and rosettes on the floor panel. Shot some rattle can primer to cut down on flash rusting. There may be some spots which will need to be welded from the bottom side, but I will get those when I have the body up on the rotisserie. For now, it just needs to be in there and solid. It is.
Moved on to the cowl bottom. I originally planned on leaving the inner brace in and just patching the outer panel. I finally had to see how bad the insides were. Glad I did it. I think I will make a new inner brace. This one is all there, but it is very thin with holes in spots. I won't have to worry about rust through in the near future.
When it comes to welding, I can go from idiot to genius to idiot in 4 seconds. Yesterday was an "idiot" day. I put in one weld I was happy with. But, I did get all of the butt welds and the plug welds done. I even started the grind process. I have also started welding the A pillar to the rocker box.
Yesterday was also "garage sale day", "get the extra set of keys made for the new truck day", "get a quote on the hail damage day", and "have the electrician out to fix the whole house attic fan day". In addition to all that, Friday night we had to rearrange the garage so we could put everything inside, away from the hail we received in several storms that rolled through. So, before I could work, I had to move everything back to the "work" location. With all this, it's a wonder I got anything done at all.
On a plus, the old truck sold. We took it for a test run in the back yard (no insurance - BIG backyard!). It ran great! I told the guy all that was wrong with it. Hopefully it will be a simple fix and he can get a lot of years out of it.
I wasn't able to work on the car Friday night or Saturday. My truck finally shot craps on me, so we went truck shopping. A new truck just in time to go to Chickasha for the spring swap meet.
Fitting the floor to this point took 2 hours and Sunday and 2-1/2 hours today. It requires a lot of hammer work and trimming to make it fit the opening and the complex curves required to mate up correctly to the floor brace. Measurements were taken from several points to assure the left side was within 1/8" of mirroring the right side. The new tranny cover was popped in from time to time to make sure this will all work.
The edge which goes under the toe board flange was trimmed back first in order for the edge of the tranny opening to end up in the correct location.
A second trimming brought the panel closer to fitting the opening. You can see down in the corner the tab for the gap in the stock floor and the rocker box extension is beginning to take shape.
The fit / cut / fit regiment is due in part to the fact that the panel never seems to go back in the car in the exact same spot. Here you can see the last mark that was made before cutting and re-installing.