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So to be clear, you cut off the entire 90 degree flange all the way around the new pans, plus a little bit of the flat part? If that is so, I'm not sure simply filling in the gaps is the way to go. Can you post some pictures of your floors and of the undersides of your rockers? The flanges of the floors are supposed to butt up against vertical flanges of the rocker panels, and the two are spot or plug welded together. I believe that this two layer vertical joint imparts a fair bit of structural rigidity to the chassis that would be lost if you simply welded the floor flat to the rockers.
What kind of shape are your rockers in? It sounds to me like there's more work that may need to be done there. And then I'm not sure that it wouldn't be worth getting complete floors and doing it right. But more than anything we should see what you're actually dealing with.
Mike
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Michael Caterino
Clemson, SC
1970 tangerine (=Tiger Orange) 'T' targa
restoration: mk911.blogspot.com
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