toolman

exterior view of firewall and rocker panel interior view of firewall Put a cardboard on a floor jack under the hole in the floor. This is used to create a template for sheet metal replacement floor pan. The hole was traced with a flet pen. Notes and measurements were written on the cardboard for reference. Always add additional sheet metal as you can always cut the extra material off. Adding material later is more difficult. I replaced the floor pan with 20 gauge sheet metal( the original was 22 gauge stuff). The pan consists of both straight bends but have curved edges too. sharedmedia=gallery:images:35465] fitting and cutting the pan aligning the pan

I used a Sunex Toon #SX278C punch and flange air tooll. There are various brand air punch and flange on the market. They are all basically the same. The cut line must be straight as the guide depends on the cut line for straightness. The resulting flange does provide additional strength and leaves a flat surface when finished. Sunny

firewall cut out--(note edges for patch are flanged) exterior view of firewall interior view of firewall frame rail aligment

When I started restoring my 240Z, I checked the Net for new ideas and procedures. I noticed a large number of restorers were not using Weld Thur Primer when when replacing new panels or repairing old ones. Weld thur primer is must on areas to be welded. It goes a long way to prevent future corrosion on that area. This because the heat from welding eliminates any paint or regular primer that was there previously. Rust proofing the area helps a little but in most cases can get into those confined areas. So corrosion can occur in only months after welding. Check out- So buy Weld Thur Primer (NAPA has it) and spray all sides of any weld( inside and outside) with it. It will give additional peace of mind. welded area before welded area primed

Found additional rust in front left side rocket panel. So I constructed additional bracing for the engine compartment. The bracing of 1" x 1" steel square tubing connects the firewall with the two strut towers. The bracing is necessary if corrosion is found in the engine compartment frame rails. Sunny rocker panel rust firewall bracing firewall bracing floor pan cutout