I am slowly removing the near and offside floor pans, I decided to retain the tunnel and bought pre-assembled floors from m-machine.
I have nearly removed all of the old floor and need to decide what is the best technique for welding the new floor to the existing tunnel. There seems to be several options.
- Joggle the new floor pan edge and seam weld along both edges, I can see this being quite strong but could form a rust trap if water gets into the gap. It can also be a 1mm or so out so accuracy isnt quite as important.
- Lap weld, which is pretty much the same as above but not quite a neat.
- Butt weld. This needs both pieces to be accurately cut. and then held with intergrips whilst tack welded
3) is my preferred approach but I am not sure how I can make a straight and accurate cut down both edges of the join. The only approach I can think of is to assemble and pin everything together with 20-30 mm overlap, then clamp a straight edge along the floor down the centre of the overlap and then run a 1mm disc down the straight edge. I have an air saw but I cannot see me getting a good straight cut with that.
Any other ideas or approaches ?
Edited by Ben_O, 20 March 2018 - 04:41 PM.