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.
The flange of the toe board received some hammer and dolly work. I also sandblasted the pits to make sure they had not softened the floor more than I thought. It is pitted, but still solid.
Then it was on to the nasty stuff. I had to clean rust and seam sealer off the bottom of the flange. Not fun. But the flange is clean and ready for weld through primer.
Rough measurements were taken. The floor piece was cut larger than the opening to allow final trimming.
The spot welds where the floor pan attaches to the toe board were drilled out. Also, the support which goes under the tranny cover screws had its spot welds drilled out. The support which goes under the tranny cover screws will probably have to be cut to match the reinforcement that the repair panel for this side already has attached. Time will tell. The cut was made from the side to the center using a cut-off wheel and the air shear. The car is now a "Flintstonemobil" waiting for the new floor pan. The spot weld operator really wanted the floor attached well to the toe board. I couldn't believe how many holes I had to drill.