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New floor pans are cut from 18 ga. steel, and plug welded to the flanges for the original floor. |
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Space the welds about 2" apart all the way around. |
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The roof is filled with a skin from a 78 Camaro, complete with the Camaro bracing. We cut cardboard templates of the roof, side to side, and front to rear, and took them to a salvage yard and fitted them to roof skins to find one with the right shape. |
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The bracing had to be bent to fit the existing flanges. The bracing is glued to the roof skin with structural adhesive. |
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The lower trunk flange was rusted, so I hammer-formed a new one on a maple plywood form, and curved it with a shrinker. The bottom flange was made separately. This was the only rust in the whole car. |