Hello all, I am wondering which is the right way to go or if it matters.
I have a 67 Cougar with big 'ol rust holes where the seat plugs go, a giant hole in the front floor to firewall area (I can see into torque box, box looks ok), and a few smaller holes elsewhere.
I ordered a 6 piece replacement set that includes the area from the back of front seat to firewall, behind front seat to rear seat, and floor to firewall pans.
I am starting to cut out the old and I have a few questions:
-Should I try to cut the old/new to match perfectly and butt weld the entire piece, or is some overlap OK? I was thinking of overlapping on the driveshaft hump and part of the firewall and butting the front and rear edges to the existing floor. If I overlap, do I need to weld top and bottom completely? Or "spot weld" it and seam seal it? I am worried about rust in the future. I think it will be nearly impossible to cut the hole and replacement panel to match perfectly. The outboard edge has a flange that I can weld to door sill (spot or completely??)
-For small areas (like a penny or finger size rust hole: should I cut out the section and weld in new? Or patch / fill with weld?
-I removed enough floor to expose the frame rail (unibody). Should I weld the entire edge from underneath to the new floor piece? Or mark from bottom, drill small holes, then "spot" weld from the top?
-I removed the parking brake cable bracket that was attached to the floor on passenger side. Can I get a new one of these? How do I go about lining it up? (unfortunately, i did not take measurements before I cut up that section)
-I searched the web for some good YouTube videos and images of floor replacement and I didn't find any "good" ones. Most were abreviated or music-video-like.
-What should I paint the new / old floor with? I was thinking brush or roller to minimize overspray but I am open to ideas.
I think we'll need to keep this thread around for awhile. I am gonna need lots of advice on this part of the resto.
Thanks!
I have a 67 Cougar with big 'ol rust holes where the seat plugs go, a giant hole in the front floor to firewall area (I can see into torque box, box looks ok), and a few smaller holes elsewhere.
I ordered a 6 piece replacement set that includes the area from the back of front seat to firewall, behind front seat to rear seat, and floor to firewall pans.
I am starting to cut out the old and I have a few questions:
-Should I try to cut the old/new to match perfectly and butt weld the entire piece, or is some overlap OK? I was thinking of overlapping on the driveshaft hump and part of the firewall and butting the front and rear edges to the existing floor. If I overlap, do I need to weld top and bottom completely? Or "spot weld" it and seam seal it? I am worried about rust in the future. I think it will be nearly impossible to cut the hole and replacement panel to match perfectly. The outboard edge has a flange that I can weld to door sill (spot or completely??)
-For small areas (like a penny or finger size rust hole: should I cut out the section and weld in new? Or patch / fill with weld?
-I removed enough floor to expose the frame rail (unibody). Should I weld the entire edge from underneath to the new floor piece? Or mark from bottom, drill small holes, then "spot" weld from the top?
-I removed the parking brake cable bracket that was attached to the floor on passenger side. Can I get a new one of these? How do I go about lining it up? (unfortunately, i did not take measurements before I cut up that section)
-I searched the web for some good YouTube videos and images of floor replacement and I didn't find any "good" ones. Most were abreviated or music-video-like.
-What should I paint the new / old floor with? I was thinking brush or roller to minimize overspray but I am open to ideas.
I think we'll need to keep this thread around for awhile. I am gonna need lots of advice on this part of the resto.
Thanks!