After Ryan jogged my memory, he said that probably the reason why the welds were not holding was from the tunnel flange not being as clean as possible. I am going to knock off as many of the plug welds that are not sticking and clean inside the holes liberally with carb cleaner and have another go around with welding.

Might want to read this first
http://www.brewracingframes.com/id75.htm

DAMN

Dsamn!

What should I use then?!?!?

I had the same problem on my first 55. I think having the heat set high enough was part of it though.
Scothbrite pads cured allot of it...

Crap Jeremy. Thanks for that. I'd hate to see Chris or anyone else hurt.

Good to know ! thanks

Ryan is right. Get it as clean as possible. Get a good ground to the trans tunnel too. I would use 5/16 holes to MIG weld the pan in since the tunnel is allot thicker than the pan. Start in the middle and burn to one edge and around. If the plug weld hole is too small, you're filling it before it penetrates the base metal. If you continue to have problems bring it out to me and we can Tig weld the problem welds.

I noticed you're using a Lincoln MIG welder. Those things come set up to weld with Flux core wire. Make sure it's in D+ and not D- with the way the ground and + is hooked up inside the machine. Check the diagram on the sticker inside the lid.

Over due post...

Ok, the cleaner the metal the better the weld.... write it in stone.

The passenger side pan half welded up 100 times better after I cleaned the crap out of it with paint prep cleaner.

I am looking for a a few able bodies this Sat. morning to help lift the body back off the pan so it can go back on the body dolly...

So who wants to help a brother out?!

Sorry man, I will be out of town or I would be there.