...well, after two late evenings at work, I got back to the bug tonight. There is some positive news...the car is no longer resting on top of the sawhorses with the pan below...but instead resting on axle stands, mostly bolted to the pan:
The problem, and one I wouldn't suggest any of you repeat, is this particular body and pan combination are meeting for the first time. First time? Yes, really. And yes, that's after paint! :-) Due to the way the project progressed I haven't actually had an opportunity to have this particular pan and body together in the same room. To make a long story short, they have both been bolted to a different body or pan...and THOSE two were bolted together at one point. So if A and B fit, and B and C fit...then A should fit C? Nope!
Front bolts up no problem, four frame head bolts and the four bolts in the front of the heater channels. Under the rear seat 3 of four bolts are no problem. Passenger side heater channel, no problem. Driver's side heater channel...no dice. Now, I know normally one might need to pull out the die grinder and adjust things an 1/8 to 1/4 of an inch, but in this case my d-side heater channel is almost 1/2" too wide at the rear corner. Hmmmm.
As the night progressed I was able to massage 4 of the 9 heater channel bolts in, with #5 just about ready to go. The die grinder on a bare pan/body isn't exactly quiet so I figured I should stop before the neighbours complain. The last three bolts (moving rearward) are going to be the tough ones. Might be pulling the body off to put some new inserts in.
-Dave