Thanks for the support guys - really... it means a lot. This is one of the most stressful things I've ever done... but it worked out (thanks in large to Scott and the other advice I've received from you fine folks here on this site).
It's in! Finally!! I got the torque boxes nailed down after measuring, measuring, then some slight tweaking, more measuring and another set of measurements, and walking away for a few minutes. Then one more set of measurements and I fired up the welder.
After the front and bottom of the torque boxes were secure, I tacked the fender aprons to the firewall, then moved to the inside to secure the 'tops' of the torque boxes (since my floor is now pretty much open in the areas around the frame rail extensions). I plug-welded all the holes from the spot-weld remover, then ran a bead along the edge for a good measure. I think I'm going to 'cap' the pinch welds as well, just for a little piece of mind by folding a strip of sheet metal around the pinch welds (making a sandwich) and run a bead along those edges as well. I'm not totally convinced my edge welds and several plug welds are going to be enough - they probably will, but I'd rather be safe than sorry in this case.
I still need to patch the kick panels and lower firewall (around the torque boxes), which will help, and also still need to weld the transmission cross-member to the frame rail extensions, but that will be for next weekend.
The big bummer is that O'Reilly Auto Parts didn't have the lower control arm cam-bolts I needed (back-ordered), so I'll look into getting the front suspension on next weekend after some finish-up work with the welder.
This is so cool! I think it's going to be OK!! Oh yeah - the pics would've pretty much looked exactly the same as yesterday's, so I got no new pics.
[/quote Rite on Eric your on your way very cool. Mike