Iím doing a shell off renovation on a í68 Overlander and near to putting the shell back on the frame, but am a puzzled by the amount of variation Iím getting lining up the subfloor to the shell.
When doing the tear-down we marked the seam position of original floor sheets against c-channel and placed cross members at each rib down the length of the shell to stop side-to-side bulging and hold the shellís form before lifting. We then used the old floor as a router template to cut the new floor. I *thought* this would make it simple to know that the new subfloor was the right size and in the right place.
The C-channel stayed on shell except on the rear banana wrapped corners, where it stayed on the wrap. When we hoisted the shell the skin seemed to be very tightly wrapped around the end corners. It took a fair amount of force from the winch to separate the corners, but that might just have been the Vulkem between the skin sheets.
A couple of weekends ago we loose-fit the floor on the frame and lowered the shell down on top. After much hammering of the sheets and shoving of the shell we got the original marks on the c-channel to line up with the floor seams for the three front sections and two rearmost floor sections, but the section between the wheel-wells was an inch too long to fit, the front wall was pushed forward from the front hold down plate, and the back wall was in the right position but bulging.
This bothered me all week, so this weekend we loose-fit the floor again, this time snug but not pushing out the front or back wall. The marks on the c-channel were consistently forward of the floor seams by about an inch, and about 2 inches would need to be cut off floor section between the wheel wells for it to fit. In both attempts plenty of c-channel rested on the subfloor.
Whatís the correct fit? Is it by design that the floor be so tightly wedged in, or was it a bad day for someone at the factory and they just wellied on it till it was in good enough? How was the floor originally assembled in the factory? Am I overly concerned by a 1-2 inch variation in the length of the shell to floor? I would hate to see rivets shearing 5000 miles down the road from getting this wrong.
Thanks for your answers, I know this is a long post.