Here is the floor under the tool box. Seem like hundreds of holes and pits in the metal. So it's all going to come out as well. But first ...
... I want to fix the hat channels. Both sides were damaged in the same spot. I know I could replace them completely with repro's but they seemed easy to fix. However bending 18 gauge is not easy unless ...
... a sheet metal brake comes on sale at the local auto parts store. I couldn't figure a way to bend a complete hat channel so I had to settle for a "U" shape which I then welded to the existing side flanges.
It makes short work bending the sheet for floors and channel replacement parts.
I welded the piece in and after drilling the holes and cleaning up the welds it is hard to tell a repair was made.
Carefully marking the bends and some grinding in a few areas made a replacement part that fit perfectly.
With the hat channel complete it was time to go back the floor. Using the same methods as previously (except I used the correct gauge steel the first time) I tacked in the passenger side floor. This main panel will have two other specially bent and fitted patches to cover compound curves - my metal working skills are simply not good enough yet to make it in one piece.
This is one of those areas. Although it doesn't look like it in the photo, the outlined area is a reverse curve, I assume to give clearance to something on the transfer case or transmission.
So after cutting out a paper pattern and transfering it to the steel I cut out a patch and with some work with a hammer and my anvil I got a patch that was really close to the original.
I then traced it onto the floor and cut it out.
I then fitted the patch in place and welded it.
I forgot to take any pictures of the finished welds - trust me they were a thing of beauty. I'm getting pretty good at it. Anyway this is after the rough grinding.
Here it is after grinding with 80 grit grinding disc ...
... and finished with 120 sanding disk. It is smoother than it looks as the flash on the camera caused retro reflections. In any event I will be giving it a sand blast to match the rest of the vehicle prior to priming it.
Body Work
With the shop nearing completion and the parts back from the sandblasters it was time to start fixing things. Learning to MIG weld and cut and fit parts is a key actiity. This section follows that work.
