Cutting and measuring-in the new Trunk Floor

The new replacement floorpan needed to be cut and fit into place before welding. This was quite painstaking to get a neat and tight fit.. The pics show the cut through the existing floorpan exposing the transmission mounting beam..


















I put-in, took-out, put-in, took-out, put-in, took-out the replacement pan..(get the point!?)..to make sure it fit perfectly; shaving of micrometres of steel until the floor fit neatly.















While the inside of the 'transmission mount beam' was exposed, I took the opportunity of cleaning it out properly and rust-protecting it with epoxy mastic..

Removing Original Trunk Floor Remnants

Another killer job...drilling and grinding out the final remnants of the original trunk floor..aghh! So first I had to clear out the previous owner's bodge floor just to get to the rusted-out factory floor..then clear all that up. Ahhh..'tis done now, ready for the next stage of the new floor going in.

Here's a pic of the tight corner with no sign of the original floor. It was impossible not to do a little damage with the spot drill and grinder but I'll weld over any little holes and grind them clean.

Tow Bracket and Bumper Mounts - clean up!

The re-inforceing brackets for the bumper mounts aswell as the Tow-Eye bracket were in a bad way following the former owner's bodge 'fix' of the trunk floor. I reckoned it was best to just cut them out and 'start again' - bearing in mind I will be using lighter fibre-glass bumpers anyway for the GT 'look'; home-made replacement brackets will probably be better.
















So here you can see I cut the brackets out and patched-in new metal. This will need to be further re-inforced before I weld in the new floor and get the shell onto the rotisserie - as the rotisserie will be fixed to the shell at this point. I can't see how the weight of the shell can be supported by the single layer of the patch without damage..


















Watch this space and you'll understand what I'm blabbering on about...!