Rear Arch and Outer Sill Replacement

[bmouthboyo]

Hi Guys,

I am currently in the process of replacing both rear arch tall panels and part of the outer sill and want to be sure how best to proceed.

I have removed the first arch the rusted part of the sill, leaving the left seam part for now. I am awaiting a spot weld drill bit so have left the arch flanges (think that's what there called) attached for now.

My first question is should I leave this seam, drill through so that I can spot weld the sill section from the left side?:



Also the sill upper flange seems to go on top of the floor along but under mid panel flange (that has the louvre window). Can I just drill the spot welds out from inside the van or are the covered but the mid panel flange? I am a little clueless on how to secure the upper flange on the outer sill . I assume I will then just but weld the cut right part to the existing.

Lastly for the right side flanges on the tall arch panel do I need to basically drill out the mid panel welds again too to allow it to come loose?

Thanks for the help so far guys, learning a lot

[Cruz]

Don't know if this helps but the original outer sill part comprises of the outer sill plus the small section of the inner floor above the inner sill (now obsolete)

Click image links below

http://t1.gstatic.com/images?q=tbn:ANd9 ... TbEZWSioaJ" onclick="window.open(this.href);return false;

http://t3.gstatic.com/images?q=tbn:ANd9 ... SUOlXZOZcg" onclick="window.open(this.href);return false;

[bmouthboyo]

Can anyone can recommend a best route given my situation.

Rear Arch Tall Panel

My main confusion here is do/can I remove the spot welds from the right side of the B pillar seam from the old arch panel or do I tack weld to mid panel. I have seen some on here tack the right side to the mid panel but I am worried about water ingress / loss of seam and not sure what route to take. Ideally I don't want to disrupt the mid panel too much as apart from the outer sill it is fine.

If I need to remove the old lip to allow for the replacement one in the seam:

1: Do I need to remove the old arch panels spot welds from the inside of the B post? And If so do I do this from the edge inside the van or the newly accessible near edge:

Interior Side


Arch Side


If Interior Side do I just remove all visible tack welds on both the arch and mid lips such as here?



Problem is it's hard to see where they are if these are the ones I need to remove

2: I am guessing either way that due to access these flanges that sit against the pillar need to be chopped off apart from the lower 2/3rds of the bottom one that I can get in against the pillar due to the outer sill being off:





If the tack method is best I assume I remove the right lips all together saving a slight few mm curve to push into the seam where I have ground out some of the old lip, them tack weld to the mid panel?

Outer Sill

My mid panel is fine apart from the outer sill where I have now cut the rust out. For now I left the old "lip" encase someone suggests it will help with my fitment:





As you can see my replacement panel has the side and upper lip on so was thinking to drill through the inner floor to allow me to spot weld the top lip, but weld the cut right side to old sill and the left lip I am not sure I can access, so not sure what to do. Adhesive

I have scoured for hours on here but as is the case no 2 jobs are the same and given my side panel is fine, and not being able to find any threads that contain pics on removing the right side of the arches B pillar spot welds I am not sure what to do.

Thanks

[bmouthboyo]

Spot weld bits here today so tomorrow will see how thatpans out. They seem so hard to locate

[boatbuilder]

Get a rough piece of sandpaper, 60 grit or something and rub it over the paint. It makes the spot welds stand out so you can see them more easily.

[Plasticman]

aye,and have you seen how sweet and virginal that handy looks, no hammer marks, rips from torn metal, ingrained oil and crud, but its early days yet
mm

[bmouthboyo]

aye,and have you seen how sweet and virginal that handy looks, no hammer marks, rips from torn metal, ingrained oil and crud, but its early days yet
mm

You can tell i work in IT lol

[bmouthboyo]

OK so today I removed the whole sill and to be honest happy I did as can sort this out:



I will remove this fixing point or whatever it is tomorrow so can get to all the rust that may be hidden:



So when I fit the replacement outer sill is it OK to drill down through the mid panel lip and floor so puddle weld it from above? And what would you recommend about the sides? The left I could tack weld to the pillar as the arch is off. Is this OK to do if I remove the flange here on the tall arch:




The right I will not be able to get access to so not sure what I can do here

Is it OK to get the Sill welded in before the arch? Will I have to offer them both up at the same time to ensure the swag line matches etc?

Regarding the arch panel

Where is it recommended to cut upto? Shall I use the full length of the replacement panel or do people generally trim it down to the first swag line? If the full length do I cut here:



And if so do I need to knock it back at all so the new panel doesn't stand proud? Any other tips?

Thanks a lot guys getting there

[Plasticman]

your first picky shows on my screen the sill closure plate affixed to the lip of the middle panal, well inbetween these two bits of steel will be loads of rust, sorry.open a bit up with a screwdriver and have a look see, it will be about an 1/8 to 3/16" in.
yes cut the lip bit of the rear wing , its meant to fit lhd rhd slider side but when you fit it on the non slider side the extra bit you can remove,
i fit the sills first and get that done, leaving room for any wing panal to slot in ,
if you have a look at kev the revs thread youn will see how and where i joined the wing, if you keep the welding to where i have its far easier to fill after as your not causing distortion to nthe panal sides. pay attention to the top corners and note how the rep panal has a cut out . you will need to reshape the vans panal where this fits to allow for a flush fit, study it well as you really dont want to cut too much off again.....
mm

[bmouthboyo]

Thanks for the reply I will be tackling this in the next few days

Can I ask when you mark on the arch above and below the inner arch for the lip you add do you add this lip in the middle of the 2 lines or on the lower one? I ask as you recommend welding it below the inner arch so didn't want to put it in the wrong place. I am guessing in between the lines is good as it will bend under the inner arch slightly to provide some tension before welding.

Regarding the cut from you Rev thread the line I marked above looks the same so that will be OK.

Regarding the corners I am a little confused as in the thread I could not see anywhere you "reshape the vans panel" to allow for the upper corners. The NS you posted this:



but couldn't see how the but under was cut and reshaped and am now paranoid about cutting too much off

Also any advise regarding the adhesive on the support arms behind the panel?

Secondly regarding rott being under the mid panel bottom lip above the sill. Would it be OK to cut out this area:



I would drill the spot welds out along where the rust is and cut it out carefully, clean and treat the underside of the lip and put in repair a piece, but welding it around. In effect replacing the bit cut out.

Sorry if I missed any of this it but it's a long thread / manual lol.

[bmouthboyo]

Quick question if anyone can help:

If i am going to be using filler to tart up the edges of a panel etc do i do that first or do i seam seal the outside first then do the filling?

Cheers

[bmouthboyo]

Any ideas?

[Plasticman]

seam seal external seams last
mm