Did some poking and scraping today and came up with some lovely holes The rail is R/S and the whole drivers Floor is R/S.All the holes in the old floor were bogged and had old underfelt glued over them even the rail was filled with bog and some plate riveted in to catch the runny bog. Scary part is the person who did it could weld as there are plates in the lower section where kick panels go. What are some people thinking ?. So cut it all out there was a bit of rust in the corner of the footwell to so cut that out. Now to cut all the good sedan floor and footwell out and unpick rail near steering box to replace it all in one section.

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No huge news here. Cut out the Radiator Hump and cut some 4mm thick steel and put a bit of a bend in it to weld in between bottom seam on front rail and meets up with the inner edge on top support . Bit of trimming and cleaning and tack it in. First Going to weld some RHS to it vertically for radiator mounts, Using gemini Radiator.

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any weld that is done as long as it is strong who cares u can clean weld up its only metal :P
i built a grader for my ute a few years ago with an arch welder and it looked like #OOPS# but it did the job, was stronger than my toe bar on my 80's rodeo ute that was built by an old boiler maker as i bet it instead of my crap built thing :P

Quickly cleaned up and tacked in place. Found it easier to leave some of the radiator support connected as i had to replace the visible part of it anyway.

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Yeah I'm a shocker mate. Unpicked the rail from me parts car today and cut out old rail from ute. Found some rust in the back of the old rail so had to unpick the rest of it. Took pics of me old rail and new one. The new one is ready to go in just gotta cut a bit more off the Radiator Support.

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looks crap

i thought you were using gas set up? gasless, even better job then. gives me hope to give it a go on some offcuts now.

.9 tip and .8 wire. thanks for the tip

Nice work Andy, you'll get it looking sweet in no time.

Thanks guys, gettin there mik. Got some nice big welding gloves only tend to wear one to hold the gun steady helps a lot. Gasless is a bit unpredictable but new metal and a good earth makes life easier to. Using the .8 wire with .9mm tip less splatter. still a few big bits to go and new tray to fit. Aiming for about a month to be ready for paint.

doing great for someone that has just learnt to weld well