Re: BigKev's 1954 Packard Clipper Deluxe Sedan

Posted by BH On 2011/8/18 9:12:02

Really enjoy seeing this part of the project, as the floor pan in one of my Patricians (originally from southern OH), though not as bad as yours, will need similar repair to the driver's side.

Looks like the C2C panels will work fairly well; glad to see they are embossed as original for the body mount locations.

Noticed your flanger also has punch. Have you considered punching the flange of the new panel and plug-welding (in lieu of spot-welding) to the existing floor? You might try backing up the plug-weld location with a copper welding spoon to help preven burn-out, if a problem arises

When finished, you could seal the joint, from both sides with flexible seam sealer. Vehcile manufacturers have been following similar practice in production for decades.

Also, you might be able to punch out the original spot-weld locations on the cross-bracing and plug-weld to new panel - though that will require working upside down.

BTW, I've no expereince in welding but in researching MIG welders some years ago, there was a weld-through primer that could be applied (over clean metal) prior to assembly, to protect the joint from rusting, yet permit electric welding - similar to a cold galvanizing compound. I'd still apply seam sealer, after welding is complete.

Just remember the old rule - measure twice, cut (and weld) once).