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I have mocked up the body with the new floorpan/firewall, both lower cowls, inner cowl braces and put the cowl back on. To assist in alignment I mounted the fenders and grill and then bolted and clamped the whole mess together. On the right side I have to make the tool indents.
I plan on disassemblying the whole thing and cleaning up the joints. Has anyone had any experience with renting a spot welder. If so any info on specifications to get a good weld. I plan on looking into that before I start drilling holes for spot welds with my wire machine.







The replacement parts I have been using are from Classic Enterprises and Midwest Military. So far I have been very impressed with the way they fit together.
One thing I noticed is that where the cowl support meets the floor board there is a hold through both and through the hat channel. I looked at the rusty pieces I pullled off and see the hole. I assume it was for alignment. If any of you have a pretty original one what was put in the hole to plug it up if anything. It appears that the same size bolt that is used in the mount inside it would fit but it wouldn't really hold anything since the cowl support is welded to the floor, the lower and the upper cowl. Below are pictures of what I am referring to.





Any observations, suggestions etc are appreciated.

If you have a mig welder, Eastwood has come out with a new welding kit to do spot welds... I purchased one but have not put it to use yet...

http://www.eastwood.com/mig-spot-weld-kit-eastwood.html

Hope this helps...

A year later I have made a little progress. I have replaced the rear floor and valence and the inside supports in the right rear wheel well and welded a patch panel in that corner.
I have now finished installing the lower cowls and cowl supports. For the right cowl I used the front half of the Classic Enterprise cowl and the back half of the MD Juan cowl since it had the tool indents that Classic doesn't make. Some body filler will hopefully hid the seam.


I have misplaced some of my measurements. There are two brackets or backer plates that are on the inside of the lower cowls up against the lower cowl support. I think the left one is for the mirror. In any case can someone give me the measurements for installing them, such as the distance from the top edge of the bracket to the seam between the lower and upper cowl.

Left bracket

right bracket
With any luck I might get some paint on this thing in 2013! Then I can start on the drive chain.

regarding your question a while back:

One thing I noticed is that where the cowl support meets the floor board there is a hold through both and through the hat channel. I looked at the rusty pieces I pullled off and see the hole. I assume it was for alignment. If any of you have a pretty original one what was put in the hole to plug it up if anything. It appears that the same size bolt that is used in the mount inside it would fit but it wouldn't really hold anything since the cowl support is welded to the floor, the lower and the upper cowl.

See the thread a few down M38 Body to Cowl support "bolt to nowhere". There was a hole and the final assembly was delivered with a rubber plug in the cowl support.

You have an impressive project going. Thanks for the update.

I might have hid my question too deep in my last post but I was hoping that maybe someone had a semi complete tub that they could get some measurements for me since I have misplaced some of my measurements.

There are two brackets or backer plates that are on the inside of the lower cowls up against the lower cowl support. I think the left one is for the mirror. In any case can someone give me the measurements for installing them, such as the distance from the top edge of the bracket to the seam between the lower and upper cowl.
I posted pictures of the two brackets in my previous post. They were taken prior to disassembling the tub.

Any help would be appreciated.
Thanks
Ralph