I want to repair/replace the floor of the 40 and I finally got out the rusted hunk of metal some PO put in and got a look at the original floor. Pics are below, how fawked am I? (the gory holes are from all the cutting it took to get the patch job out)
I am thinking of cutting out the major stamped sections, one for the fuel tank and one for the t-case, and welding them into a whole new floor. But then I wouldn't have the small stamped sections that reinforce the floor. Can I spot weld reinforcements on? Alternately, think a good sheet metal shop or stamping plant may be able to stamp in some reinforcing ridges? It doesn't have to match original and I don't want to pay for custom tooling. I am looking for ideas here.
I am also wondering if divide and conquer might be the way to go. I was looking at it tonight and wondering if i could take the floor out in 4 sections, one at a time, repairing each section then replacing it. I would cut along the rail that reinforces the floor from underneath. Anyone tried this?
I am primarily interested in options that involve fabrication, not buying replacement parts.
I should also probably add the caveat that I am not attempting a faithful restoration, I want to weld some new metal in (but do it well) and get the 40 painted and rhinolined so I can go back to working on mechanical mods. I am tired of it looking like s***e.
I am thinking of cutting out the major stamped sections, one for the fuel tank and one for the t-case, and welding them into a whole new floor. But then I wouldn't have the small stamped sections that reinforce the floor. Can I spot weld reinforcements on? Alternately, think a good sheet metal shop or stamping plant may be able to stamp in some reinforcing ridges? It doesn't have to match original and I don't want to pay for custom tooling. I am looking for ideas here.
I am also wondering if divide and conquer might be the way to go. I was looking at it tonight and wondering if i could take the floor out in 4 sections, one at a time, repairing each section then replacing it. I would cut along the rail that reinforces the floor from underneath. Anyone tried this?
I am primarily interested in options that involve fabrication, not buying replacement parts.
I should also probably add the caveat that I am not attempting a faithful restoration, I want to weld some new metal in (but do it well) and get the 40 painted and rhinolined so I can go back to working on mechanical mods. I am tired of it looking like s***e.
My first sheet steel experience was a friggin disaster. 
