Hey all, wanted to do a mini build thread on a 40 coupe Im workin on. Its a bit of a street rod so I wont do the entire build. This car came to me "ready for paint" But its a basket case and Ive been redoing everything. So Im still doin the sheetmetal work. Currently Im on the floors, inner rockers, outer rockers and lower cowl and quarter areas. Tryin to decipher the correct route with the hacked up body mounts I came here lookin for some possible pictures but with no luck. So I decided to do this post for anyone in the future in search of info and pictures in this area. It was known the car needed rockers. But when the outers were cut off it showed a whole mess on the inside. As usual a can of worms. The floors were not nice at all but the owner did them so I was tryin to salvage them, but it is to the point now that they will be re done also. Here are some pics showing how ugly it looked cut in for paint by the previous shop. The middle of the doors touch the rockers. And holes in the drivers side. The car never saw the road, and sat in a garage. Here in the quarters rust holes were welded and hammered in. Some areas were 5 layers thick where only two layers should have been. The owner made half his floor pans out of eighth inch steel The idiot that made the inner rockers screwed up so they had two pieces hacked together to make a smooth inner rocker. This is the rear body mount. Note the sweet nuts welded together. This Ive finally figured out should be a carriage bolt like the rear trunk body mounts. This is the center body mount all boogerd up. All the ugliness cut out. After being dissatisfied with reproduction parts for the price you pay for them I am making everything from here on out. This is a piece I made that is the lip of the floor. This was made before I planned on re doing the floors or otherwise it probably would have just been part of the floor pan. Here you can see how far off the floor is. Here you can see better detail of the piece how it is stepped for the rocker, then the big bead for the sill plate. Here are all the side pieces mocked up with the new floor piece. The rocker overlapping the floor piece. This is the inside at the rear body mount. (above the nuts welded together)
A little better shot of the nuts. This is what was really stupid. They had this boxed area that was totally out of place and didnt make any sense at all. (note how in the next two of pictures the pinch weld seam just disappears) There were horrible patches in that area in the floors so I made up a new one. All beads and bends done. Fitting to car clamped in place. Under side view where it meets the floor extension piece. Ive been gas welding lately, so here are the two pieces tacked. Welded. Back in car welded together. This time the floor patch is in from the bottom side until everything is trimmed. Underside again. Everything back together with the sill plates on just to check fit. Ill get more up tomorrow hopefully or over the weekend.
The Jalopy Journal
