Here is a very pleasant diversion from the usual stuff I work on:
Why do I say it is Flintstone style?
I hope you can figure it out without me needing to explain it.
Here's the new 18g panel to get put in:
I was surprised by the interior:
Possibly the best part of the car:
Marking, trimming, wash, rinse, repeat:
After a few more hours of carefully doing a little tweak hear, a touch more grinding there, I got the panel to fit well.
With the pan in place, I traced out the supports and then marked spaces to drill holes:
Pilot holes to verify measurements:
The holes matched up perfectly (thanks to careful measuring) so I popped the rest of the pilot holes:
All of them lined up with the flanges on the supports, so I drilled them out to about 1/4" in order to get a decent imitation spot weld:
The sun was setting, so I just busted out the rest of the welding and did some other patchwork underneath the car that I didn't get pictures of.
Here's the final product:
It's rock solid, with very, very little deflection even with all of my (fat) weight on it. It will last a very long time, too, especially with the right treatment of the panels. underneath and on top.