Replacing inner sills

[fidget]

Dunno if you still have it but keep the old crossmember with the original number in it to prove why it now looks like it does now!

I dont want to point out the obvious but I have edited out the chassis number for the picture( didnt think it was to good a idea to publish my chassis number on the t'internet).Hence it looks some what better than the photo, not factory but a passing resemblance

james

[fidget]

well , when I say I was making sure nothing went missing , I really meant skirts were never that short when I was young so stuff the neighbour and his shed I had to check who was attending this party purely on a security related basis

James

[Plasticman]

Thats more like it, pickies?
M

[jamesc76]

Dunno if you still have it but keep the old crossmember with the original number in it to prove why it now looks like it does now!

I dont want to point out the obvious but I have edited out the chassis number for the picture( didnt think it was to good a idea to publish my chassis number on the t'internet).Hence it looks some what better than the photo, not factory but a passing resemblance

james

Erm i did get that cheers!!! Did you keep the old one tho, as you put not factory!

[fidget]

[quote=Erm i did get that cheers!!! Did you keep the old one tho, as you put not factory![/quote]

Yep Im keeping the old crossmember, By the time the new one is painted and undersealed there wont be much to see .

be interesting to see how it fares come mot time.

Mike the pictures are a waste of time , the state of them poor old chavs this morning when they stumbled out the front door has ruined all illusions (gotta love a teen hangover) talk about dawn of the dead.

Just for the record the neighbour is still trying to put up the shed

James

[Plasticman]

Go on then picky of the shed, always worth a laugh
mike

[Plasticman]

James, ref the measurements I gave you, the size was literal and not the socket, ie the hole should take a bar of the diameter I stated and not a socket of that size
mike
(shed pickies)?

[fidget]

Cheers mike

I got what you meant . No chance of pics Im afraid, my man flu has upgraded to call a priest Im dying .

3 hrs sleep in the last 24 not good , off work as well now. It must be bad as im not allowed to leave the bed even to work on the van. My argument that I can still weld laying down fell on deaf ears

James

[Plasticman]

Just done the same job on the Hinklevagon ,get in there and give it stick when your up, (priest my ass)
mike

[fidget]

Slow progress again but none the less progress has been made

Battling with a duff regulator on me gas bottle and bank holiday DIY

anyway, new b-post base





once the sill was welded in place the old sill semed to loosen up and further poking revieled a new hole



a few words with the yoda of the welding stick resulted in this







Last bit of the new sill flange in place



Base of the c-post/jacking point area replaced, total pig to fabricate but pleased with the way it turned out



will do the lower left corner when the new bit of rear arch goes in in. Im not proud of some of the welding but anything that can be welded from both sides has been

Mike me front jacking point alignment problems seem to be getting better . Im trial fitting the outer sill and have had to hammer the flange of the inner sill to get it to fit which has made aligning the jacking point easier . Still not great but less head scratching. Have got to rework the flange of the outer sill as in no way shape or form does it match the inner sill flange , hey ho

James

[Plasticman]

Right , you see your bottom picky,the open bit to the rear, well weld in a bit of good steel so it welds to the top of the suspension mount and fills the gap, then add another bit over this and puddle welded to it,this will match up with the bit you have already done, this will give you much needed strength and is easy to do,
that hole is in the actual suspension mount really worn through , anyhow what you done is fine, about where this rot hole is , there was an 8mm hole (vw wisdom , maybe jig location) left open, so I suppose water and all sorts will have found its way into the seam over the last 20+years..
As for the front , your on the right lines, dont fear thumping metal , all these pattern bits require it to a lesser or greater degree, do waht you need to make life easy and get stuff aligned,
mike

[fidget]

Cheers mike

You can see the in the 3rd and 7th picture that the bit I cut out was shot and werent worth trying to save. (lower left corner). I made all the c-post repair panels at work this morning as we had the sparks in up=grading the power supply. So got paid time and a half to make bits for the van . Down side was I left all me 2mm steel at work so couldnt finish the corner.

James

[dugcati]

good to see your progressing albeit slower than you want but hey that's life aint it!

keep at it and keep taking the pics

[fidget]

Right

Ive had a couple of weeks off but am back on it, Ive been faffing about trying to make a c-post post in one complete peice . This is the end result



Looks good , just about got it to fit , ran out of gas, had to bite the bullet and get a throw away bottle from halfords. Get back have a prod to check the welds , zero penetration, culprit is me duff regulator again . Stripped it down again still no joy , take the knob off try again and a nice flow of gas again. The knob was bottoming out when fully wound in even tho it still needed a few more turns to fully open the valve . Not even a year old so thats going back monday morning.

Me work of art c-post section was b******d so all had to come off, gave up making it in one piece so went for 3 pieces instead





finished and primered



Trimed the rear wing section to fit , and dug out the remains of the old one, Last week I had to rework the lower flange on the outer sill panel as nothing lined up. This is the results of a quick trial fit





Ill have to admit these 2 are my favourite pictures this year , even tho theres loads still to do it looks like a van again. The rear wing is a schofield one and included the arch section . It was 3mm to long so I decided to cut it to fit the old rear arch and will weld a new flange on it to spot weld to the arch.

I know it looks like a bomb site but thats a well ordered mess

Now just got to sort the b-post out and they can all be welded in place

James

[Plasticman]

Thats really really good there, You were right to do it in 3 bits, no point making work, I should know,, I bet its nice now that you have replaced the inner jp and you are welding new metal to good new metal , perfect, looks like a van again and the repair panal looks to have joined as seamlessly as can be ! go have a beer
Mike