This is very timely.  Over the weekend I found how bad the soft spot in my
floor pan really is:
http://s629.photobucket.com/albums/uu13/rickas47/Floor%20Pan/?action=view&current=Floordamage005.jpg
I started by picking at it with my finger and opened it up this much in just
a few minutes.   I need to finish removing the interior completely to survey
how bad it really is.  I'll be asking for support soon.

On Tue, Sep 29, 2009 at 4:36 PM, <[email protected]> wrote:

> Hi Don, i prefer to butt-weld any sheet metal used on the outside of the
> car, as well as the floor pans, i just feel that the overlap of the flange
> just creates a place for rust to start, but its easier to clean up the welds
> -- and i think the factory used the flange welds on the floor pans- there is
> a way i have seen that i would like to try with a tool from HTP 12002
> notcher, which creates a "V" and then you weld at the base of the "V" and
> creates less grinding, but would not look very nice on a panel you could see
> from both sides. and the tool is almost 100.00.
>
> Harlan
> http://www.hkaa.webs.com
>
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>
> In a message dated 9/29/2009 4:15:39 PM Central Daylight Time,
> [email protected] writes:
>
>
>  I'm looking to settle a dispute between two friends of mine...
>
>
>
> When replacing sheetmetal floor pans (or other panels) one friend says it's
> best to butt-weld the panels together and grind each side clean.  The other
> says all edges should be flanged with a crimper and welded on one side, seam
> sealed on the other side.  Personally I have done both but never bothered to
> clean up the welds.  The second argues that the floor is not as strong when
> butt-welded.
>
> What is your preferred method?
> --Don
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-- 
Rick Schaefer
72 TPI El Camino

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