First off this thread is absolutely one of the best things I've ever seen on the internet! Thanks for all your time put into detailing and picturing everything! just one question. It looks like your drilled holes in the floor to spot weld onto the supports, did that penetrate well with the rust encapsulator sprayed on it? I want to coat mine too just wasn't sure how well that would work when welding the floor back in. thanks in advance.
Wow thanks for the comments. There are quite a few really detailed builds on here as well as the IH parts america readers rides forum. I usually try to look for posts that have multiple pages cause it usually means the project hasn't stalled. Lots of good info and inspiration.
To answer your question yes I got excellent penetration on my plug welds. The metal was pretty thick so I was able to turn the heat up pretty high. Once the floor panels were laid onto the floor braces I take a pick tool or screwdriver and stick it down into the plug weld hole to scrape away the paint just in that spot. I realize some of the paint burns away during the weld but I was trying to coat as much metal as possible to prevent rust in the future.