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We used an air grinder with a cutting wheel. Worked great.
Just a thought when we changed mine we decided we needed more room in the cab. We cut all the floorboard forward of the seat out, than brought the firewall straight down another 8-10". Now the floorboard is flat all the way to the firewall. This moves the pedals against the firewall down low and gives the driver much more leg room.
i've looked on ebay and seen plasma cutters as low as $300 and has high as $2000.
Are the cheap plasma cutters good enough to do the job, or are they like welders? You can't go cheap??
I would think that the cheap ones would do the floors... they are probably 16-14 ga. material... but I wouldn't expect much more from them at that price/amperage...
What do you have for a plasma cutter? I have to do body repair at some point and I respect your opinion on this stuff. It seems you've cut out a lot of things over the past couple years. (that was NOT intended as a slam)
A cheap sawzall with some metal blades is the low buck tool to own if you can't swing the expense of a plasma cutter. For 60 bucks you can make very clean cuts in materal much heavier than Effie frame. I use a jigsaw or an air cutoff tool to cut most of my light sheetmetal.
I like a 4" or 4 1/2" angle grinder with a cutoff wheel. Inexpensive and fast, Don't need to cut deeper than the panel thickness so you can save crossmembers and reinforcements. Only thing you can't do is cut into a corner. You see them used a lot on the TV hot rod/biker build shows.