Penny

[Shark_13]

Oh geez! No going back for sure

[Getter-Done]

Great job so far.

With a Welder and a 4 Inch angle grinder Miracles can happen.

[cwcarpenter98]

A spot weld chisel worked well to remove the floor pan. Could not easily see the spot welds with how terrible the floor was. Looks like the new pan is going to fit well once trimmed up and fit to the remaining good parts of the original. Plenty of trimming left to do before anything gets welded together

[cwcarpenter98]

Finally took some time to work a couple hours on Penny last night. Got more of the bad cut out and was finally able to loosely mock up the new inner rocker. Had to set the new floor in just for fun

[Android04]

Stay motivated, it's coming together nicely

[cwcarpenter98]

Originally Posted by Android04

Stay motivated, it's coming together nicely

As usual, I end up working on it a couple hours and then life happens and I don’t touch it for weeks. Planning to take a day soon to just spend all day working on it

[cwcarpenter98]

Made some time on Monday evening to get the initial mock up of the floor and rocker panels done. Looks like itÂ’s going to come together well.

This evening, I made marks on the backside of roughly where some cuts should be made. While making those marks I remembered that I had not replaced the cab mounts yet, so I finished this eveningÂ’s work time by doing just that. Thankfully, all the bolts came loose without too much fuss, all the frame mounts were solid with just a smidge of surface rust, and the new mounts bolted right into place without a fuss. Now that those are replaced, I can begin cutting for the final fitment. Definitely going to test fit the door and fender before making any heavily permanent welds.

[Shark_13]

Great progress!

[hewittca]

Nice work so far! I am going through the same process of replacing my outer floor section and rockers. It's crazy how much time it can take to get everything to line up. It is definitely worth the effort when you have all new metal installed.

[cwcarpenter98]

Originally Posted by Shark_13

Great progress!

Thanks!

Originally Posted by hewittca

Nice work so far! I am going through the same process of replacing my outer floor section and rockers. It's crazy how much time it can take to get everything to line up. It is definitely worth the effort when you have all new metal installed.

Thanks! It always ends up taking longer than ya think, but definitely worth it in the end. I’d rather make a bunch of cuts inching closer to the final fit than to cut the patch panels too short and have to add metal or get a whole new panel and do it again

[cwcarpenter98]

Speaking of cutting to fit, I started slicing on the floor pan patch today. Also hung the door and fender back on to check fitment of everything. Obviously, nothing is fully trimmed and in place yet, but loosely installed still was fitting up nicely. It is going to be way better than the rusted out floors and rockers when I am done.

It may seem unrealistic, but my goal is to have the cab rust repair welded in by the end of February. This year will be the year I drive Penny out of my driveway.

[cwcarpenter98]

Made some major progress this weekend. The patch panels had a good bit of overlap between the floor pan piece and the inner rocker. Spent a good bit of time trimming and fitting up until I felt comfortable enough to start welding the two pieces together. I welded the front and back side of the seam just in case.

Before starting to weld, I did fit the door again with all the patches in place to make sure it was gonna be ok. Looks like it will turn out fairly well. My goal is to have this side done by the end of the month and then the driverÂ’s side done by the end of February.

If I end up doing this again on another squarebody, I’ll probably just replace the entire floor.

[cwcarpenter98]

Floor pan and kick panel are welded in place. Threw down some primer while the weather was decent enough yesterday. Next up is outer rocker, cab corner, and repeat on the driver’s side.

I’ll be slathering the welds and as much of the other seams that I can get to with seam sealer before final painting

[62 Barnfind]

Nice work! I just brought my 73 home from storage and I have to do the same on both sides? I have done pans and rockers on my 62 and 57 but not on a square. It looks like they all stack together

[cwcarpenter98]

Originally Posted by 62 Barnfind

Nice work! I just brought my 73 home from storage and I have to do the same on both sides? I have done pans and rockers on my 62 and 57 but not on a square. It looks like they all stack together

I ended up cutting the floor patch and inner rocker patch and welded them together before welding that assembly into the truck. Seemed to work out ok that way since it was one solid piece from GM. If I get another square with the same amount of rust, I’m buying a full floor pan for it instead of just patching it.

[cwcarpenter98]

Outer rocker and cab corner welded in this weekend. I’m at a place where im comfortable with moving on to the driver’s side to get the bulk of that work done. I’ll finish both sides up by applying seam sealer to the welds and seams.

[cwcarpenter98]

Started on the driver’s side yesterday. The floor tried to put up a fight, but I got it out. Still have some spots to cut off, but for the most part, it’s looking ok