Hey guys, thanks for the kind words.
Mike, thanks for explaining the others the additional info. Yes, it all has been done in a short time. I pushed it into my garage mid september so it took 2.5 months so far. Only evenings and weekends.
The mini tubs...
As you can see in the pictures we have cut out about the whole stock tubs except 'the rail' on top of the stock tubs. When you look at a stock tub there's a 'T' (an upside down version) model rail on top of it all the way from the front lower part (integrated with the inner body where the body panel attaches to) to the rear where it meets the trunk floor again. Except for the last part of it in the trunk (see pics) I left that rail alone. The cut the stock tub at both sides of that T-rail so the stock tub is loosened from the T-rail. Everything else has been cut out. With the electic saw? I cutted the part along the chassis. This loosens the inner side of the stock tubs. With a cutting wheel I cutted the wheel lips (left a bout 1/2" for strenght and to prevent cutting yourself ) This loosens the outer sides of the stock tubs. Then cut the floors at the width of the tubs so the whole stock tub is loosened. (from one to another cut) Now you will find out there are some more braces on top of the tubs which you can't see. You have to play around a bit with the cutting wheel then...
The above result can be seen in one of the pics.
Then start measuring approx. sizes of what size you need to fab up the upper part of the tubs. (around 60x20 inch) and get that in house. Get some cardboard box in pieces and go line out the outer shap of the body where the new tubs reach the body so the new tub follows the body. If you have that done attach the cardboard as you would attache the new tub. Then start measuring from (every couple of inches of the cardboard) the distance from the inner side of the cardboard to the outer side of the chassis. Write it on the cardboard where you measured it. If you have done this you remove the cardboard and lay it flat on the 1mm (or what size you got) steel plate you got and redraw the outer body lines on the plate. You just have measured so you can draw the inner line on the plate also. After this you have the upper part of the tub drawn so cut it out. Now it takes some strenght and tricks to get it in against the T-rail mentioned earlier. You will see you have to make quit a bend where you reach the package tray, I used a long screw there to pull the tub plate inside the corner. Go on placing the plate against the T-rail. When you have it in place in a way you want it (could take some attempts to place it nicely) give it some wleds so it stays there. Check all your alignments to your satisfaction. If it's ok go on with the following.
When you have cutted out the stock tub you will notice the floor is loosened from the chassis because we have cut out the outer lib of the chassis rail. Where the floor meets the chassis, weld it fully close. After that grind the weld flat with the chassis. Then start measuring / drawing (with cardboard again) the steel plate needed for the insides. When you have cut it out making it fit perfect put it in place, hold it there and give it some welds. Check again if everything is to your satisfaction.
If so you can start welding the whole thing (T-rail to tub, inner side of tub to chassis, inner side of tub to upper part, etc.) I have welding points about every half inch. You notice to make it all fit nice and to cover some bad looking poieces you have to cut and weld some small strips and plates at a couple of places depending on you cut the tubs out and your body model. If you have done this you could (if you need/want) fab the plate between the tubs. In my case it's needed by safetly rules for racing as I will have a fuel cell and batt in the trunk. After ALL welding is done in that area you put sealent over all welding lines. Make sure you get one sealent which can be painted!! ALso seals the line where the upper outer part of the tub reaches the body. Check from beneeth to see if you have it all 'waterproof'
Then it's ready to paint.
If I ain't miss something this is how I have done it. It's quit simple, just take your time and measure / draw / cardboard things first. Once cutted you can't go back...
Looks great.
