I know that I will be going over old ground, but I want to be sure before I weld.
When you have put in the boxing plate and are aligning the outer floor extension do you try to curve the bottom of the boxing plate to match the curve on the outer floor panel, or do you simply let it meet where it meets and weld it there? Or, is the a totally different method.
Thanks,
Steve.
The easiet way to make these parts fit (RP109/109A) is to stretch the end flange by knocking it with an hammer against an anvil or other improvised hard place. I use a length of heavy box section for this, trapped in my workmate bench/vice. Rest the bottom flange of the panel against the top of the hard lump with the panel safely out of the way below the hammer blows. Start at one end and using firm knocks work your way down to the other end. DO NOT HIT IT TOO HARD if you do you will over stretch the thing and you will then have to resort to cutting shallow 'V' slots in the panel to let it go back. It is better to repeat the operation two or three times rather than make an annoying mistake. Remember that the curve is progressive so keep checking the panel for fit as you go, some areas will need more knocks than others. TAKE CARE. Remember that the flange also stretches outwards and in order to fit the other sill parts you may have to grind back the end of the flange in places before you start assembly and welding.
Remember the old saying, "measure twice and cut once" and apply it to all jobs that you do.
