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Been working on the replacement brace a little.

I used some 1/2 inch square tubing. Heated and bent it around a pipe I tacked to the table. It worked out really well. As you can see in a couple of the pictures, the contour of the bend matches the old brace pretty well.

I used some 18 gauge sheet to skin the brace. I would have liked to use some 16 gauge, but I couldn't find a piece big enough laying around the shop, so I used what I had.

I wish I had a bead roller!!! I wanted to stiffen up the sheet metal a little before welding the tubing in place. I used a flanging attachment for the air hammer and ran a flange down each side. Luckily, the flanges are exactly 1/2 inch wide, perfect for the tubing I was using. Didn't plan it, just lucked out.

What a difference the flange makes in stiffness.

So then it was just a matter of welding on the tubing. The pictures don't show it well, but I used a series of stitch welds on the outside edges and tacks on the inside. I managed to get it burned in without warping the hell out of it.

I also repaired the seat brace that runs perpendicular to the floor bracing. The middle portion was the really bad part, the rest was pretty solid. I laid in a new piece of sheet metal over the bottom and repaired the outside edge with another. Good as new. (Well, as strong as new anyway)

I've got a few other things to do before it can all go back in the car for good.

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Keegan,

Great description, great pictures, great ability, great job!

Quote: Keegan,

What is the significance of the deadline? From my rough calculations that would be 19th June. I had meant to ask this earlier but I think I've now found the answer here.

You are 100% correct Mal.

I've set a goal of driving it to the "Back to the 50's" show this year.

Lot's to do before I can marry the body and the frame again. I just hope I remember how everything fits

I should have used my free time to work on my taxes today. Meeting with the accountant next Tuesday. Somehow I just couldn't bring myself to do it. Had to keep working on the Clipper. At least I can measure my progress with the car. Taxes and bookwork never seem to come to any measurable end.

I welded in the new brace and the seat brace as well. Then I started to make some replacement panels for the floor. I've found that my limited skills are best used to make smaller panels and fit them together. Rather than a large panel that covers it all at once.

With the help of many clamps to hold it all tight together, I was able to cover up about half of the floor that I've removed. The large missing section will get covered by the floor pan that I purchased online. Once that one is in I'll move to the toe board.

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Been slowly chipping away where time permits. Hopefully I'll be able to fill the big holes soon and move onto the Oh-so-many little holes.

Got the big piece test fitted with the help of some sheet metal screws. It needed some extra help to fit, but it wasn't too bad.

It takes a while, but eventually you get all the spot welds connected to make a solid repair.

I've started the toe board repair as well. I'll finish weld it all when I've got all the patches in. Hopefully the drivers side floor will be done before next Monday.

It will look much better after some time with the grinder and some seam sealer to smooth the rough edges.

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Quote:

You've got to be kidding!

for the compliment Guy!

Really, I'm making this all up as I go.

Got some time today to finish up the patchwork quilt that is my floor. The toe board is buttoned up for the most part. There are some smaller details that need attention, but at least the broad strokes have been laid down.

I'm still debating on removing the dash. On the one hand it will make some of the next steps easier. On the other hand, it's one more step to go through for reassembly.

Hopefully I'll start the rockers next. I won't have carpet for a long time, so I'm thinking of running the wiring through the rocker panels for a cleaner look. I'll try to see if that's a reasonable goal as I hang the replacement panels.

17 weeks and counting. I'm afraid time is not on my side.

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YOU'RE KEEGAN

I like the way you are labeling each pic, as well. It's very helpful for understanding the process, and should help you and other readers in the future too. These project blogs can become virtual manuals with the right documentation and labels.

Rocker panel #1.

Started the drivers side today with the hopes of having both sides done by the end of the week.

I was lucky enough to have the outer panels included with the purchase of the car. I'm sorry to say I don't know who made them, but they look like they will do nicely. They are a little long (better than the alternative) but other than that the fit seems good.

I started with inner panels. They're 18 gauge sheet with a broke 90 that fits up against the underside of the floor pans. I chose to make them in two pieces because it was just plain easier to fit. They are a little taller than needed, but the excess will trim easily once its all welded in.

With the inner panels temporarily in place I sized up the outer panel. The panel doesn't have a cut-out for the center door post, so I had to bend the sheet metal back a bit to go around it. You can see in the photos the panel will need to be shortened, as it sticks quite a bit past the front of the door.

Once I was happy with the fit and location, I took it down to prep the panel for welding. I dug out my handy little hole puncher and used the 5/16 die set to knock out holes on the top and bottom for plug welds. I figure every 2.5 inches should be plenty strong enough.

I want to get a couple coats of weld-through primer on the inside of the panels before I weld them in. I also plan on drilling some drain holes as well to hopefully make this a one time repair.

I was surprised by how much the look of the car changed with just the addition of the rocker panel. Sometimes you can work for days or weeks and not get that sense of accomplishment that can come from such a simple thing as hanging a single piece of steel.

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