Got yet another update...we took last week off...busy getting ready for our big move....we are all moved in to our new place (just not unpacked)...I spent a solid 4 hours on Thursday, measuring and cutting in the new section of tunnel...and then my friend went and ruined it by going crazy with the plasma torch! (see the pic)
He seems to think we can float in some extra metal in the weld and repair the unnecessary cutting....but really...we're talking over a foot of metal cut out!
See!?
Oh yeah...sure...it had rust....:P

And he wants to mess with all his new metal shapening doodads...
Jokes aside...we got in there and started tapping around the driver's side pan...it was rusted pretty bad...so out it came.
The new section of tunnel is SOOOO close to fitting correctly...I just need to cut down a few more edges. Then it'll get all nice and cleaned up. After that we start the put it in place.
I bought some Herculiner on eBay...truck bed liner that you can apply with a paint roller...we are going to power wash the underside of the car, and then apply the liner...I'm a bit concerned about living right next to the ocean now...so this should help keep more rust away.
Ted