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Hello Lonnie, nice to see you are still enjoying your build.
The family is doing fine, we have had some trials lately and I will pm you seperately on what I mean by the that.
As far as your questions go, you are correct, I did make my upper left and right side curves by tracing out the pieces I needed on 16 ga sheet metal and then box welding it all together, for me it worked out fine and didn't take all that long to do. I added a photo, probably not the best one but should explain it easier than I can.
My scuttle is fastened in place with grade 8 bolts, I wanted to be able to dismantle everything as easy as I could should the need arise. So I can remove the scuttle, not necessarily in five minutes but a relaxed afternoon if needed to replace it if it was damaged. Same with the steering column undue the end joint and four bolts and it is out.
The dash is held on with threadable inserts in the one inch tubing.
I also rolled a 1/4 inch bead of 'dum dum' between my scuttle and the frame before I bolted it down, this I had left over from the AMX, it stays pliable and makes a watertight seal, so if I get caught in the rain I don't have water seeping its way into the back side of the scuttle through the seam.
In fact I also used it on the outside tubes of the frame before I put the body panels in place, not so much for the water but to cut down on any resonance the aluminum panels might have against the 1 inch tubes.
I also did as you say welded my floor completely around the frame. I did this by starting on the outside edges of both outer sides, jumping front to back with my welds. Once I had the outside done I worked in towards the center tunnel part by tacking the floor to the cross braces my seats would be mounted to. My thought was to make sure that the metal moved towards the center of the car as I welded it., the very last part welded was the center portion of the floor under the driveshaft tunnel. My thought was that if you weld all the way around the perimeter of the floor first then it will heave enough in the center to maybe oil can on me. I have never had any oil canning in mine at all, so maybe I did it right or it was just dumb luck. I also have checker plate in the footrest area, it might also help, though I did it for aesthetics and to have a reinforced area under my feet.
I ground the weld smooth around the outside perimeter of the floor just enough so the side panels would fit snug. There is a bit of overkill there anyway as I then used yellow large head 3/16 rivets to attach the side panels through the floor into the frame. So the floor in essence welded as well as riveted, just the way it worked out.
I still have the cycle fenders on, I kind of like them, I still have not used the old clmshells to make patterns, that said my wife would like to see the clamshells back in place.
My front fenders are from Fenders N More. I got them quite cheap early on as did a few others, but from what I gather they raised the price quite significantly since for some reason.
The rear fenders I got through Jack but they were the wide ones from Curtis not the 'steam rollers'.
Hope that helps
Al
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