How do I fix this? I expect I need to do something before welding in the floor pan. It is difficult to see, but the lip from the rocker is gone by the kick panel up to the body mount brace. Also the brace itself is has been cut or ground away from where it meets the kick panel.

I need major help. I hope I can but weld a piece of sheet metal where the rocker lip use to be.

Also, What do I do with the drilled out spot welds in the body mount brace?

Thanks, Kevin

pic1 (http://www.chevelles.com/showroom/kmchugh/bodymountbrace.jpg) pic2 (http://www.chevelles.com/showroom/kmchugh/cutoutfloor.jpg)
pic3 (http://www.chevelles.com/showroom/kmchugh/cutrocker.jpg)

ttt

Thats a tuff one. What new metal do you have to weld in? Floorpans? New rockers?

Actually, your rocker panels are OK! That inner piece with the lip is exactly as it should be. The floor pans had a lip that rolled over 90 degrees and sandwiched between the body mount and the inner cowl. Unfortunetly, the new floor pans do not have the original style lip. I think they assume that you would have enough of this left to weld to. Both sides of mine are gone, so I just plan on welding in a filler section when I get the floors finished. I'm also planning on replacing the mounts as they are rusted out also. (Convertible uses double mounts in front for extra support).

Gary

Clark, I have new floor pans to weld in.

Gary, if you look close at pic 2 you can see there is no lip on the rocker from the brace back about 7" or so. I cut it out and ground it flush with the kick panel. Also, the brace is missing some metal where it ites into the kick panel. I was thinking of butt welding in a piece of sheet metal to replace the rocker lip. Is this a good stategy? Or should I try to fit the floor pan to weld to the kick panel?

Also did I need to cut the rocker where I did?

I know I should not have cut along the top of that brace (pic 1). How do weld that back up?

Kevin, that is the end of the inner rocker panel. What you cut and ground off forward of there was the rolled lip of the floor pan. The lip of the pan continues forward and is sandwiched between the cowl panel and the body mount brace. If there is enough metal on the pan to roll a lip that will reach the cowl do that. If a rolled lip won't reach then make a lip. Trting to weld the floor pan 90 degrees to the cowl panel won't be strong enough. Since this area is covered, you can make the filler panel "L" shaped and fit to the top of the pan and inner cowl surface. I had to do both sides of mine and cut the lower cowls and braces out of several cars to get enough good pieces to fix mine.

As far as welding the cut above the brace, just do it like a butt weld on a patch panel. Make sure the body is sitting at the right height on both sides of car before welding. Did you support the body before cutting above the brace? Check to see it isn't sagging as that mount carries all of the weight of the front of the body.

Gary