Welding in new panels

Post by **maverick** » Sat Nov 21, 2009 9:31 pm

I recently bought two new floor panels and a welder for my pick up and am keen to get them put in. The question i have is that where should i cut the old ones out?
Do i leave like a 1 inch lip around the outside of the cab so that i can weld the new panel in with it resting on the lip?
Thanks in advance

Post by **bmcecosse** » Sat Nov 21, 2009 9:41 pm

The purists will say you should NOT have any overlap - butt weld, grind flush, weld again, grind again - until the join is invisible. Be sure to disconnect the alternator (if you have one) before doing any welding!

Post by **les** » Sat Nov 21, 2009 9:50 pm

There are lots of overlap joints on a minor around the floor and cills, so maybe if you keep the overlap to a minimum, say 3/8-1/2 inch and use seam sealer you will be ok.

Post by **cormorant** » Sat Nov 21, 2009 11:19 pm

If you are going to overlap the joints probably best to use a joddler and this will pre form a neat overlap for you. You could both plug weld and seam weld.
Wouldn't get too worried about water entering joints in a floor pan, I mean these cars had no rust protection from the factory bar being sprayed in cellulose so if you flood all the joints with smoothrite and a couple of thin coats of underseal with waxoyl you are providing a lot of protection.

Post by **Longdog** » Sun Nov 22, 2009 6:19 am

Hi, my method was to use a jodler and have approx 2mm over lap all round the panel with the overlap uppermost. By the time you weld around this your weld pool will "heal" the over lap and you will essentially end up with a butt weld. With a good coat of underseal you can't see the join.