The drivers side rear torque box was replaced the weekend before last. I fit and cut the replacment floor pan and dropped it in this past weekend. It was much easier to do than the passenger side for no other reason than experience. I learned before that clecos are my best tool for holding the sheetmetal where I need to be be. Clamps are good but just dont work in every situation. I cut a bit too much metal out of the tranmission tunnel from the seat support pan and the transmission crossmember. The gap is just a bit too wide to weld alone.
I’ll deal with the gap by placing a small piece of copper sheeting behind the gap and weld it closed. The weld will not stick to the copper. This will allow me to support the weld pool and bridge a larger gap between the sheetmetal pieces. Otherwise, without the copper, the weld pool would eventually drip on the floor and I’d just have a big mess and a larger gap to repair. I used a 2″ copper pipe, cut it down one side and hammered it flat because copper sheeting isn’t exactly sold at Home Depot and is expensive where it is sold.
