Here is a shot of the new sheet metal prior to priming/installation.
The inner rocker panel is on the bottom of the photo (note the
rust where it was handled), and on the top of the photo from left
to right: Floor pan (holding up the sheet metal), toe pan/floor
pan extension, frame patch (small), and passenger side TB.
Close up of area where passenger side TB will cover.
A hard hit on the old one has caused enough rust that I was concerned
for frame long term integrity. I cut out the floor pan support/frame
extension and welded the new piece of sheet metal over the remaining
metal. Note I have used a combination of rosette welds along with
a bead along the perimeter. I have ground the area and applied
the weld thru primer in preparation for the installation of the
TB. The picture is shot from the front passenger wheel well.
Close up/bottom view of above. I have applied rust
converter to the areas inside here I cannot reach with a grinder
and used Rustoleum rust metal primer over that. It will not be
accessible once the floor pan is re-installed.
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