Thread: 49 More-door build

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Originally Posted by falconvan

I didn't have much of a choice, Robin. Just standing on it I felt like I was going to go through and hit the ground.

Wow, this was worse than I thought once I started cutting. The drivers side was worse so I'm knocking it out first. The bottom 4 inches of the B pillar was gone as was 1/2 of one of the braces and the inner rocker. It looks like someone had put a new outer rocker on right over the old rusted out one at one point. So I didnt have to remove the old rocker, it just fell out on its own once I started cutting. I'm not fixing it all right now; just building a structure that will support the floor and give me something solid to build from if I decide to go back later and go further with it.

Oh,yum..been in places like that before.. Just gotta take a deep breath and immerse yourself in it..Very satisfying when its done though..Lookin good,mate..Keep going..

The other side was easier; lots more solid metal to work with plus the braces were all in good shape. I've got one section left to do; should be able to wrap it tomorrow.

Last few....

Looks fine Falcon!!! Going to have a nice, solid floor in your new driver, for sure!!!! One thing I've found about doing the nastiest parts of the build first, it sure does make the rest of the work seem pleasant!!!!!!

That's good advice, Dave. Do the worst first and it's downhill from there!

Pretty much finished the floor today. I had a few spots with some small pinholes so I rust proofed them and hit them with some All Metal filler; as soon as it dries I'll do all the edges with some seam sealer and paint the floor with some POR-15. Next we move onto the brakes!

Ok, that's about as far as I'm going with the floors. I seam sealed the edges and the welds and hit the whole thing with POR-15. Next I'm going to start on putting the brakes together; I should have everything I need. I also pulled a complete front to rear wiring harness out of a Olds wagon a friend of mine was scrapping. With some slicing and dicing I think it'll do the job fine.

Looks good!

"..... Next I'm going to start on putting the brakes together;......"

Yup, you get one thing done and there's always the next step. I finished up my floor (for now) today, I'm debating wether to hang the Dana or build the steering next.

Now that's one heck of an improvement on the floor, turned out great!

After all the rust and other nasties, the rest of the project looks like a cakewalk, huh???

Yeah, this was definitely the worst part of the car so I'm glad to have it done. Now for brakes and get the flathead up on an engine stand to crack it open and see what we've got.

Much improved. Replacing rusted out floors is a thankless job but the way you did it is the right way. You won't have to worry about pulling a Fred Flintstone anytime soon.

Don

Thanks, Don. It still needs work on the rockers but at least I know there's something solid to attach them to if I ever decide to do it.
Here's what I came up with for the brakes. The old master cylinder was shot and I wanted something with a dual resevouir anyway. This one is a replacement for a 67 Fairlane. The old one had the pedal pivot incorporated into the casting so I had to build a bracket. It came out great; bolts right in where the old one was and the pedal is in the correct location.

Back from Vacation and Falcon you have did another great job . As said no one see's the floors but it's nice to know while in the driver seat you have some solid work to rest on . Congrats .

Thanks, BS! I hope you had a great vacation. Yeah, if the worst happens and I have a fender bender, I'd like the floor to have enough integrity that the seat will stay attached to it.

Over the last few times in the garage I've got all the front wheel cylinders replaced, new shocks installed, and all new brake lines plumbed in the front. Still need to do the rear but that's coming up later. I got the broken seat slider fixed and the front seat back in, plus got the engine up on a stand so I can take a look at the inside. I've got a few days off so I'm going to try and tackle the wiring some cleanup and repair on the inner fender wells in the front clip, and maybe get the oil pan pulled from the motor so I can get a look at the bottom end.

Getting along very nicely......great job on the floor......no more Flintsone Mobile..lol