Toe Boards Jan 20,2013

Got some work done on the passenger toe board today.  Decided to go another route and patch the rough area rather than trying to fill-in the holes.  Used the extra pieces of the half floor pan from what I cut out the toe board patch.  It is the same gauge metal.

First – rough cut the opening:

IMG_0088

Next, place the cut out piece on the patch panel to be cut out for reference:

IMG_0090

Cut around the outside of the tape – I want the patch panel to be larger than the rough cut area:

IMG_0091

Mark what needs to be cut out on the toe board:

IMG_0092

Cut inside the marks to give some wiggle room:

IMG_0093

Double-check the patch panel covers the cut out hole:

IMG_0094

 

All that remains now is to grind down the opening to fit the patch panel and then clamp and weld.  I need to order the proper grinding discs – hope to have by next weekend so I can finish it off then!