Do the job right! That’s been Eastwood’s motto for a long time. Taking that motto to heart, I couldn’t walk away from the previous episode of Project Sunny feeling right. Sure, I got the two pieces of the floor stitched together into one piece, but I wasn’t happy with how it looked. So I swallowed my pride and went back to, well, you know… do the job right.
The source of my dissatisfaction was primarily the misalignment of the floor contours at the seam. the aftermarket panels I’d purchased weren’t exactly precision engineered, and when I mashed two of them together to make one piece, the ridges were clearly inconsistent. I was also not satisfied with the top-to-bottom alignment of the panels, and that was on me.
I chose to cut out the old welds, realign the ridges, and re-weld the two parts back together. Half of that went pretty well, but I soon found myself trying to bridge too big a gap where I’d cut the previous welds. On such thin material, I was starting to blow out most of my new welds.
Remembering a recent tech article on welding blow-through, I adjusted my process and was able to salvage the work. In the end, the realigned floor is much better than before and should look original once it’s finished. Here’s the true final episode (I swear) on how we fixed the rear cargo floor. Watch the video to see what you think.