After a few more rounds of grind and check I am getting pretty close. Score and fold for the tunnel works nice. I ground all the sealer and paint off the floor where my welds will go.
Decided to take the engine out for better access to everything:
I forgot how messy the place gets when everything is out of the car.
Here I am closing up the end of the old exhaust tunnel tubes. The one on the right is done. Just trying to keep moisture out mostly.
For whatever reason, both sides of my new tunnel met up poorly with the floor. I welded on some extensions. Other side is fully welded to keep out moisture and provide strength. This side is tacked for now.
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