I'm finishing my rustproof and new diamond plate floor on my D1.

-I ripped almost everything out of the interior.
-I power grinded and wire brushed the floor.
-I cut out small bits of unrepairable rust.
-I used KBS Klean to remove all residues.
-I used KBS Rust Blast to burn the rust off and prepare for painting.
-I used KBS Seal in black to cover all exposed metal and create a hard finish.

-I made a template of the floor in order to cut the diamond plate just right. I need to finish positioning of bolt holes for seats and belts.

To do this weekend...

-I need to find a good panel adhesive and some marine caulk to finish up the floor.
-I plan on running some galvanized metal strips along the perimeter to strengthen the floor support.
-Cut and patch the few wall or front floor holes with sheet metal to cover exposed holes. Patch and paint.
-Weld a couple stays to the floor.

I'm getting on it shortly.

Note: That third pic demonstrates my saggy ***.

 

Here's the template. I can probably save it for anyone who needs it.

 

looks like your daughter is going to fail elementary art class now that you stole all her construction paper.

 

too funny

 

Ed - Actually she'll probably fail geometry. It looks like a twisted map of the US. Art supplies we got...all over the place.

 

I think it would make great garage wall art.

Looking good, you should be done by Día de Reyes.

 

Honestly, what you should to is transfer that to a piece of 1/4 hard-board. Trace it out, rough cut it, and sand/file down the edges.

Now your hardboard is a working template. Do your final fitting with the hard-board... Take off a little with a file here or there as needed. Drill your seat-belt holes, fuel pump hole, etc.

Now you have a final template....

Transfer that to your aluminum plate. Cut it out about 1/8" bigger. Trace it with a carbide template bit on a router (your gas tank hole too). Now you have a PERFECTLY fitting piece of diamond plate AND a PERFECT template that you (or fellow enthusiast) can use over and over again.

 

DB....Why do that extra step? Your way is museum quality. I'm doing above hack/DIY and many shops level but not made for TV. I can lay this down nicely on the diamond plate. Tape the outline and then use my cutting wheels on my hand grinder. It's tight but I allowed for shift. I'll definitely file down the edges. That's not going to be hard.

 

It's definitely going on the workshop wall where the headliner now hangs.

 

And should be signed by all persons involved with the project, down to the pizza delivery guy who has kept you going...