After measuring all the major dimensions on the shell to verify nothing had moved during the rocker installation, I came to the conclusion these were just lousy reproductions. I marked where the floor pan deviated from the toe board seam and made a cut.
This cut separated the pinchweld seam on the floorpan and allowed me to bend in into place against the toeboard. Now it was just a matter of making a panel to fill in the gap.
PIC 1: The new panel tacked into place. If you look closely, you'll see a second fabbed piece on the right hand side where the pan mates up the cowl and inner rocker
PIC 2: Everything welded and the floor put into place. I now have a nice, tight fit with the toe board. But I'm not ready to weld it into place yet.
PIC 3: The drivers side pan has the same problem. You can see how much metal I needed to add to make the pan fit properly
