Thanks for the replies. I've done my fair share of welding at a prior job, mostly stick welding and MIG on thicker sheet metal, so this thinner welding is somewhat new to me. When I cut out the old toeboard, the cuts will be straight, not curved. It won't be straight across from drivers side to passenger side in on continuous cut. Alot of the cuts will be on 90's and 45's. As far as using the copper for backing. After switching from CO2 to 75/25 (argon/CO2)I tried it on some plug welding this weekend and it worked great. Was able to create a nice weld pool. Thanks for the advice on that one TPYLE. I'll be getting the new sheet metal this week and hopefully will start working with it this coming weekend, depending how I feel after my 20 year class reunion! I'll post some pictures in my webshots to show the progress when it happens.
