David's GT6 Journal

I just can't get motivated to work on The Beast. I'm paralyzed with... something. It's not indecision; I know what has to be done. I think it's _fear_ that I'll (again) screw something up. Seems like the car doesn't get any better for my having worked on it...

Yesterday I wrote 'Next up: trim again, test-fit again. Then, if all is good, mark off where the trans tunnel and driveshaft tunnel need to be trimmed. Then, trim it, and maybe start welding. "

Today I trimmed some more, and test-fit the floor. And finally took to heart some advice Elin Yakov gave me. I'm constantly worried that I'm going to cut too much, or ruin something. He said "you can always weld it back together, or add more metal, or get a new part".

So I started cutting. I cut (wide) the remains of the floor. About 3/4 the way through, it was kicking back a lot of sparks and it was bothering my arm, so I got my welding sleeve from the bottom of my (homemade) welding cart.

Then I saw the rust... the bottom shelf of the welding cart, and one of the pieces of the bottom part of the frame, was badly rusted. I had noticed some of the small spotty rust on the top, but nothing this bad. I don't know how I didn't notice it happening, but I suppose "out of sight, out of mind" applies here.

Painting the welding cart has been on my 'to-do' list for a while, but I was hoping to alter the top shelf to have more of a "lip" around the welder itself. But, I never got around to it, preferring to work on the actual CAR instead...

So... I took everything off the cart, removed the hardware (wheels, eyebolts, etc.) and started cleaning. I wire brushed the shelf (expanded steel) and flap-disked the rest. I did two coats of primer but they didn't cure in time for me to put a topcoat yet.

Maybe tomorrow I'll get back to, you know, the CAR...

I've test-fit the floor probably 4 or 5 times. I've trimmed it near the trans tunnel, and down along the driveshaft tunnel. It's still not fitting 100% but it's getting there.

The only thing I'm worried about is that I think the metal is starting to fatigue. I think I've noticed new ripples and bumps where there were none before... hopefully I haven't done more damage than good.

Next up: trim again, test-fit again. Then, if all is good, mark off where the trans tunnel and driveshaft tunnel need to be trimmed. Then, trim it, and maybe start welding. Somewhere in there I'll need to prime the floor, and parts of the rest of the body.

Then, I need to fix the firewall (and its flange) where it was rusted through, and torn off. Luckily I bought a shrinker/stretcher so I'll be able to form the flange appropriately.

Evidently the "heritage" floors sold by Rimmer Bros are not that accurate.

The bracket that goes under the floor ("dashboard support", near the end of the outrigger) won't fit within the pressed shape.

So I took action. I cut the (NEW!) floor, formed it into a better shape, and started to weld it back together.

Did I mention I have no idea what I'm doing?

As usual, I make some progress only to be stymied at the next step...

I finally got the last little patch of the driver's front floor out. I think I mangled it pretty nicely, but it's out.

Then I tried to dry-fit the new floor. Hilarity ensues: https://youtu.be/xhTjiaC_SSI

After much struggle, the footboard section of the driver's side is almost out.

The only part left is under the body mount bracket. Seems that the floor was both spot-welded to the flange on the firewall, but it was also seam-welded inside the bracket to both the firewall flange, and the bracket itself.

Is this normal? It's very frustrating, having only a 2 inch by half-inch piece of metal between me and trying to install the new floor.