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more floor pieces
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simple die press
Forming the plugs
I used some PVC fittings that I had lying around and a large socket for the inside and formed the plug pieces on my shop press. It helps to go gradually and hammer the edges flat as you go.
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The Die
Here is the PVC pieces I used. the small cap fit inside the large one and served as a "stop" so I didn't press too deep
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The die pieces
This shows to two PVC pieces assembled and the socket I used to form the inner diameter.
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The finished pieces
These are a few of the finished pieces next to the old one I used for a pattern. There are six in all, I made them all in an afternoon.
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upper panel
These are kind of out of order, but I wanted to show what can be done with a bead roller, this is the upper foot rest pattern I made using the old one as a guide.
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wooden buck
I also made this "buck" out of some scrap MDX. Since I could not form 90 degree corners on my bead roller, I created these grooves with a router. I lined up the grooves in metal with the grooves in the wood and hammer formed the corners with a rounded pick hammer.
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Recent News
Here's the new panel next to the old. I drilled the spot welds along the bottom edge but had to cut the top with a cutting wheel as it is actually a part of the firewall You can also see the flange that I bent with my metal brake. The front edge of the floor pan will lay on top of this and be "spot" welded to it just like the factory did it, only I'll be using a wire feed MIG welder. I also used a metal punch to create holes along the edges of my panels to simulate the original spot welds.
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And here it is welded in place; it lined up very well with the grooves in the firewall. In one of the previous photos you can see where the new floor pan was welded in and onto this panel.
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