I have two new replacement panels for this sections just in case I need them. Looks like I will on at least one side. 

 

Excellent posts and very good of you to document so well!

This is older stuff.  I've been incredibly remiss in posting as I go.  Most of this work was done two years ago.  I'll throw some more photos together and continue to post.  I have a ton of stuff.  Right now this is how the car looks:

 

 

Charlie Osbourne makes the best floor boards in my opinion. Stampings are really close, with a little massaging on install the repairs are invisible...

I have a set of his floor panels in my shop, waiting to go in!

ksechler,

you are really close to being "All down hill from here..." I think getting through finish paint is the hardest part of this kind of project.

 

In areas like behind the drivers side wheel where you repaired it, I always use a skim coat of fiberglass over the weld seam before using filler. The fiberglass fills any pin holes in the seams and prevents water from coming in from the backside and causing bubbles. Pointed this out for anyone else doing this kind of work. No reason for you to go backwards at this point. 

ksechler,

you are really close to being "All down hill from here..." I think getting through finish paint is the hardest part of this kind of project.

 

In areas like behind the drivers side wheel where you repaired it, I always use a skim coat of fiberglass over the weld seam before using filler. The fiberglass fills any pin holes in the seams and prevents water from coming in from the backside and causing bubbles. Pointed this out for anyone else doing this kind of work. No reason for you to go backwards at this point. 

 

 

ksechler,

you are really close to being "All down hill from here..." I think getting through finish paint is the hardest part of this kind of project.

 

In areas like behind the drivers side wheel where you repaired it, I always use a skim coat of fiberglass over the weld seam before using filler. The fiberglass fills any pin holes in the seams and prevents water from coming in from the backside and causing bubbles. Pointed this out for anyone else doing this kind of work. No reason for you to go backwards at this point. 

 

Thanks!

Funny the thing that turned the project around is I changed jobs and got rid of a 2 hour commute.  I work on the car almost every day.  

 

Frankly, I do a lot of rework.  For example, I put the hardlines on and off the car multiple times.  First the old rusty lines to remember how they went, identify the right hardware, and weld new mounting points (replacement floors didn't have any).  Second time, to fabricate and put new lines on.  I botched it and third... my second attempt to fab new lines, which I nailed.  Then everything came off (and got labeled a lot better) and I painted the undercar and engine compartment.  Finally, fourth, the hardlines went back on, I put in the suspension and took it off the rotisserie.  Four times to get it right!

I like the dedication!

ksechler,

you are really close to being "All down hill from here..." I think getting through finish paint is the hardest part of this kind of project.

In areas like behind the drivers side wheel where you repaired it, I always use a skim coat of fiberglass over the weld seam before using filler. The fiberglass fills any pin holes in the seams and prevents water from coming in from the backside and causing bubbles. Pointed this out for anyone else doing this kind of work. No reason for you to go backwards at this point.

Pat, do you mean fibreglass filler by itself or cloth fibreglass plus filler?

Sorry to derail...

No mat just the fiberglass. I use an Evercoat product that is catalyzed the same as body filler. It's green before adding the catalyzer. It is a little thicker than body filler. Smear a thin layer over your welded areas after they are ground down. If you have a pinhole it will fill it so water can't come up through it from the back side and bubble the paint. body filler is not water proof, the FG is

Here are some photos from the engine compartment.  I went through a phase where I didn't take too many photos so I don't have much to show.  The engine compartment work went hand in hand with me sorting out the undercar, hardlines, and fuel delivery.  Somewhere in there I did some *gasp* welding on my gas tank to repair pin holes, which I have posted elsewhere.  The engine compartment was sandblasted and a couple mounting points welded in for my brake proportioning valve and fuel pressure regulator.  Enjoy!

 

Here's some work under the car.  The plan and sequencing went like this:

1. Put on the old rusty hard lines to remind myself where they went.

2. Bend new ones (wrong)

3. Re-bend the lines (right)

4. Weld on new attachment points for the lines

5. Mount the tank, new (aftermarket) fuel pump, and (aftermarket) fuel filter, which included welding in mounts for the filter and pump

6. Put on the suspension to sort out the hardware and verify there is no interference

7. Take the whole works off (I labeled and packaged the parts better this time -lesson learned)

8. Prime, paint and undercoat

9. Put all that crap back on

 

 

 

Here are some pictures from my work on the hardlines and fuel pump: