Need some floor supports that go from the bottom of the A pillars across to the transmission tunnel. I had a good pair of stock ones but they were too short and made for the original floor pan which is on an angle there. Also had saved some ends from the donor, but decided in the end that it would be better to make new ones from scratch.
Folded up some hat channel to start with.
Cut a T at one of the ends and placed it on the corner of the bench ready to flatten out the fold.
Knocked out the fold ready to make the wider end that braces against the bottom of the A pillar and floor support.
Cut some shape into it like the original ones.
Bent the cover piece over a solid bar with the nylon mallet.
Tacked in ready for welding.
Now I had to clear the flange where the new section of floor joins to the donor floor. Rather than just cutting the flange away I thought I would press the clearance in
With the longer piece taped underneath I placed another couple of pieces of scrap each side of it on top. Then taped them as well.
Put it all in the vice and did it up nice and hard. Gave it a hit with a bolster until it left a mark in the tape right across showing I had the depth I needed. Raised it up a bit and it it again with the bolster to get the outer edge done as well.
Shows how I clear the metal now.
Did the end bits as well to clear the flanges on the floor supports. The factory just cut it instead but thought might as well do it this way to get a better seal and stronger too.
Holding it up you can see how it clears both flanges now. I actually shorten the hump a bit before welding it in.
Now for the other end. To terminate it like stock it needs to go up inside the tunnel a bit. This reduces any stress rises. Just marked the flange where it last touched the floor and then cut to that point. Bent the flange around the corner. Placed a straight edge on the tunnel down past the end of the support to get the angle and how much to cut off for the rest of it.
Made an end piece after putting a bit of radius at the top. Can see the stock one next to it that I am getting my ideas from.
Welded up and ready for fitment.
I zinc coated just the inside of the support. I drilled the holes through the floor rather than the flanges as get better welds than doing it over head from the underside. I cleaned the coating off at the weld points, even though it is a weld through coating. Less chance of any porosity and going to burn off anyway this close to the weld.
Was getting late and the dog came to let me know! wink emoticon Some weld penetrates right through from the top leaving little mounds.