Sunday, April 19, 2009

Interior Restore - Part 8 - Firewall - Toeboard

Matt and I got out in the shop this morning and did a little work.  In addition to the full floor pan being replaced, we also needed the toeboards replaced.  This is the angled piece that joins the firewall to the floor pan.  

I didn't take a pic of the passenger side before we started, but here is a pic of the drivers side.  As you can see, it's pretty well rotted away.  We were very fortunate that the frame rail extensions that the toeboards weld to are in good shape.

We started with a toeboard repair panel from NPD.  This is 18 gauge sheetmetal that is stamped in a shape that closely resembled the original shape, but it was far from "drop in and weld" piece.

We were having a very difficult time getting the complete unit to fit properly, so Matt cut the repair piece in half.  This worked out much better.  Here is the right side welded in.

Here is the left side of the repair panel trimmed to fit.

Left side mocked up and tacked in place.

And the final unit welded in.  The piece but welded to the firewall and trans trans tunnel and plug welded to the frame rail extensions and where it meets the floor pan to duplicate the factoryh spot welds.

Interior Restore - Part 7 - Welding Lesson

Decided to let matt try his hand at welding.  Probably should have done it sooner, but I am just learning myself.  He actually did pretty good.  We did a few plug welds and stitch welds.  Not bad for a first time.  Click to enlarge each image.

Finished plug welds

Some Decent Penetration on the backside