Hi All, Getting closer to fitting my new complete crew cab floor in place but it has got me thinking should I: Drill and plug weld every rib on all the top hat rails or bond some and weld the others !!??
VW spot welded every one, but spot welds you can chop off with a bolster. Try that with a plug weld! i.e. plug welds are far stronger than spot welds. If you plug weld at every point there was a spot weld you might find the floor panel turns into a big dipper, so I'd advise not doing so. If you stagger the welds like the following, IMHO it's enough welding to adequately secure the floor without warping it. I went for 1 in 3. Then use up all your old paint as nobody will see it (though maybe they will in a crew cab).
Cheers Zed the job has just got easier. You painted the top hats before how did you then clean off the paint to weld ? I was thinking about zinc weld through primer ?
2-packed the lot then marked through the holes in the floor and cleaned up small areas. Some surrounding paint will have burnt off but a great deal will still be there. I don't think weld-through primer is water proof and as such seems a wee bit pointless to me.
Ok so i might rustproof then hammerite or chassis black the rails first then mark with tippex to clean and weld.
if you drill you bed in place, it marks all the places your gonna weld and cleans off the paint at the same time, obviously don't drill right through
