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I reckon Harv is on the money again. Laps are easier and on my floors I have used them where the centre tunnels have been replaced. Common sense tells you that where the lap ends, the weld will be just as brittle as a butt weld. Personally I will be a bit surprised if there are ever any stress cracks on floor panels except maybe on the firewall ones where there is a bit of flex. Might be different with 300hp v8 though. In terms of rust, copper primer and then paint over seam sealers. I've seam sealed every join on my old girl, whether I welded them or original.

This all makes me laugh !

The car can can be driven around with holes everywhere from rust, bogged over and painted and no one would ever know.

The floor pans are normally welded to other structures and to date I have never seen a floor crack around a butt weld. In my early days I have oxy welded the floor pans in with little or no grinding required. These days I weld with the mig, faster and less distortion from the heat.
I have also run over the weld of a mig with a oxy in the tunnel area, again though I fully welded a brace under the tunnel and over the top.

If the welding is done correctly then the edge nearest the weld will be where it cracks and to be honest it will have to move around a lot for that to happen. The reason welds do crack is because the weld is usually ground down to make it smooth, most cases removing the thickness of the metal and that's where it would most likely crack.

Hi tensile welding is stronger that mild steel but in essence needs to be done correctly and there will be no issues.

As for the rust between panels its a good idea to treat it again with rust preventative before you seal it, nothing like a car rusting from the inside out !!

Greg

Everybody is right

Thanks for all the advice lads. Appreciate it. Just going with what the engineer says. Looks ok for a trial fit up

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Cracking along now.. starting to come together.

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Some progress

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Good stuff. Getting stuck in to it Mick.

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Thanks mate. Its been a bit more than I expected. Once everything was blasted there was plenty of rust. At least inner and outer sills were good! Couple of little patches at the front outers but otherwise all nice and solid. I'll pump them full of fish oil when ive finished. Wish I had have dipped it rather than blast. I simply cant get rid of all the media. It keeps coming out of every nook and cranny!

Been there. 20 years later still coming out from under the dash, and I only blasted the window surround.


FB ute fixer upper, EK van on rotisserie

Hey Mick, you're making it look too easy! Looking good

Thanks Brett
Measure twice cut once is my motto. Im sure I could be further ahead but its still too darn cold to be rolling around on the factory floor here in Melb.
Hopefully we'll get some warmer days soon. Then I'll start to make some progress.