[Prowbar]

Went ahead and tackled the floor, which had some holes in it. Didn't think it would be this bad, though. Replaced all the sheet metal that looked like the landscape of the moon...

Bought a new kick panel, had to change the location of the holes to make it fit but otherwise fit fine. Made a complete floor section out of multiple pieces, replicating the original, including the bend section where the floor panels are spot welded to each other.

When the floor section was tackled, I welded in the bottom A pillar.

We have access to a portable spot welder, used this where I can to replicate the factory look.

Gave the new section a good coat of paint and spot welded in the rocker. Had to rework the rocker quite a bit to match the original, and cut and weld all the stepped sections to fit the contour of the cab properly. When all was said and done, the rocker was spotwelded in.

Took quite a bit of time to do it properly, but am satisfied with the repair. The door fits in great and the gaps are nice and consistent. New door seals are in as well.

Next task is to remove the front window and weld in a new inner roof section.
There is some rust in the roof as well, in the upper a pillar and outer roof section as well. Drip rails need to be cleaned and re-sealed. Will probably be a heck of a job. That repair has the most priority because of the severity of the rust, but wanted to do this repair first to get the hang of sheet metal work, then move on to the more challenging tasks.

For now, the truck is back on the road and I am enjoying her again. Maybe in a few months I'll start on the front window.

I figured out my mysterious driveline noise and am working on a fix. It ended up being in the SM420 transmission. This will be shared in another thread in the transmissions section.

Also had issues with a intermittent misfire, that ended up being caused by one of the PCV valves. Capped them off and am using a Ford 460 PCV oil cap now, just like sclor posted on the forum.