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Old 12-22-2012, 07:53 PM
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For the floor the 1x1 tubing if welded correctly and enough is used to get strength that should be a fine system to rivet and zoosk (sp?) fasten the aluminum too. As for the kick panels and any other rusted panels you need to repair.....use a 4" grinder with a 1/16 cutting disc to remove the rusted metal. Try to keep lines as straight as possible and be sure to keep the piece you cut out. Use the piece you just cut out as a pattern on replacement metal by using a medium point sharpie to draw aroung the outside. Cut to the outside of you mark (the width of the marker line is about the same as your cutting disc) and viola, you have made a perfect fitting patch panel for flat surfaces if you want to butt weld them in. If you want to lap and spot wled the panels just use the piece you cut out and add 1/4" to the size of the cut out when marking. Use a flanging tool to make a flange all the way around the outside and drill holes where you want to spot weld the panel. Hope this helps a little.
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