Toe boards

The replacement toe boards (or floor pan to firewall patch panels) I had , had flanges in the outer edges bent downwards. Obviously they would fit in a car without torque boxes. In addition, the diagonal upper flange on the torque box points up which makes the area for toe boards narrower.

So I measured and cut the excess off of the boards. To decide how much the original metal could be cut the boards were test fit. The boards would well cover the pitted areas I wanted to cut off. Anyhow, I wanted to save the openings for steering column, parking brake cable and others.

The bad thing about fitting the toe boards is that they do not fit correctly until they are cut correctly. Therefore I only cut them slightly and repeated the cut and fit process many times. Finally the edges of the metals met each other and the toe boards could be pressed against the torque boxes and the flanges in the frame rails. After drilling the holes for plug welds the boards were paint and welded.

Defining where to cut

Torque boxes have been prepared 

Driver side toe board prepared and cut to fit

Toe boards welded

The recess on the passenger side board matched correctly with it's counterpart in the torque box. I had a blackout and  drilled the plug weld holes not only to the right excess but also in the left excess which does not have any metal behind it. They are only three of them and will be plug welded when I'll finish the seam welds under the floor.