I wasn't able to get to it right away, but I did stick the fender and door on in order to check the gaps. As the pictures show the gap at the back of the door is really tight, and up front it is a little wide. If I had really spent some time adjusting everything I probably could have had everything lined up better. I was really just looking for consistency and that the gaps were at least even on the sides and bottom.
|Really tight back here, needs to go forward a bit. I don't have it closed all the way.|
|Gap just looks bigger than it really is due to the angle.|
|See, it doesn't look to bad.|
|Lines are straight, looks good.|
|Before paint. Ugly!|
|Scuff a little here, scuff a little there.|
|Cleaned and painted. Looks good. To bad it will never be seen again.|
I fit it, marked my holes, pulled it off, drilled them out, and reinstalled it. Checked fitment one more time, clecoed and clamped it into its final resting place. Now for those of you who are wondering, the box installs over the frame rail flange. This is how the factory did it. There is a great diagram in the assembly manual that shows this. If you have an earlier car with out a torque box, and you're not replacing the toe board, you may want to do a one piece box as that would be easier. That way you can slide it under the frame rail and just drill straight through the toe board for attachment.
|Drilled and ready for hot, molten metal.|
|I swear that the auto darkening helmet has improved my welds significantly. I can't believe I didn't get one to begin with.|
|It really feels good to be able to fill this ugly hole with metal. I have been staring at it for way to long.|
|Goodbye unnecessary piece of metal.|