1984 Chevy Custom Deluxe

[crackerhigher03]

I am new to the board and have a 1984 Chevy Custom Deluxe that was orginally had a automatic transmission. I was able get a munice sm465/np205 combo from a 1975 Chevy Scottsdale 4x4 and the complete setup pedals,etc. I am getting ready to do some body work on it and replace the rusted panels including the floor because of the rust pits. When I installed the clutch rod through the floor, the hole ended up being bigger than it was suppose to be. Does someone have a picture of the factory clutch rod hole in the floor pan by the firewall?

[thump16]

where are you in north florida? I may be close enough to you to help out.

[crackerhigher03]

I am about 30 mins away from Tallahassee. Here is a pic of the hole that I made. I would like to weld a new piece of sheet metal in with the correct size and location of the hole that the rod goes through.

[Slick17]

I'll try to get a pic for you tomorrow. I have a 84 custom deluxe also.

[crackerhigher03]

Ok. I have another question on welding in new sheet metal. I am usings a 90 amp flux core harbor frieght welder using .030 flux wire. I had grinded down the rust to bare metal and there was some holes in some places and the metal was kinda thin. I decided to cut out the thin piece with the holes in it and fit another piece of sheet metal then try to tack in. I noticed when I grinded down the welds that that there was some tiny pin holes in the welds and when trying to seal those that it would blow a hole right the metal. Would like to get a decent MIG with gas to do cleaner welds but its not in the budget now. I have had a few ideas cross my mind such as either brazing these panels in oxy/acy or either just fiber glassing over the ruff areas and sanding it down smooth. This will not be a show truck but I also do not want to open the door and a rocker panel fall off one day.

Does anyone have any tips and suggestions for doing this?

[crackerhigher03]

One other thing. I have the amperage on the welder set to low. I also had the wire speed on about 3.

What should the wire speed be set to and also how far should I be hold the gun away from the metal?

[Tex_50613]

well as for the pin hole problem, that is a common occurance with flux core welding, try turning up the heat and wire speed just a little on the welder (not sure about the settings on a Harbor Freight welder cause I use a Miller)
and the gun should be held no more than 1/2 to 3/4" away from your work (commonly)

[crackerhigher03]

Thanks. I will give that a try and see what happens on a piece of scrap metal.

[Tex_50613]

Originally Posted by crackerhigher03

Thanks. I will give that a try and see what happens on a piece of scrap metal.

no problem, if you get good penitration then do a little grinding to smoth it out with a final skimcoat of fiberglass it should look verry nice, as for me I am rhinolining my entire floorpan as soon as I finish the mods to the hump, I have a 3" body lift and twin sticked a NP205 t-case so now I have to drop the floor around the t-case shifters 3" to be able to use a boot with them, I ended up cutting a big dang whole in the floor to acomidate the swing and I don't like the looks of it