Offside sill

[rainman]

I don't see it at a false economy, I've also bought a fairly cheap mig and hope to be able to patch up my van. It's not worth a lot in its present state and I've no intention of selling it anyway so it's just a case of keeping it on the road for as long as I can. I'm not that bothered about making it perfect, I just want to know it's not going to turn into a pile of rust.

[nenenaiad]

Hi All.

Have spoken to a few people and it appears that when it seems that there is no seam then you are looking at a sill repair done some years ago.

I have been looking around for a diagram which shows the original panel layout for the offside, but I have not found one so far.

I can imagine when the original sill was replaced it being removed from the lowest joint at the bottom of the sill and then cut at the horizontal seam. A replacement would then be spot welded to the bottom flange and to the upper seam and then filled.

But then years later we are off again.................!

Keep watching this space. It will be a week or two to finish the arch and then on to the sill.

Regards

Dave

[Cruz]

See the picture of the VW part i linked to above to see how the sill looks in all it's originality

[Cruz]

This was how my van looked

Outside Pic 1

Inside Pic 2

As you can see over the last 25 years the lower outer sill panel has completely rotted thus making a gaping hole in the floor and the seam gape open where the lower outer sill meets the side panel. Sadly it also affected the inner sill very badly.

The van is currently in the workshop having the inner sill (bought from Germany, no UK stock), lower outer sill inc. inner floor area (VW UK) plus a piece made up to replace the side panel from the seam to the swage line with a new hole for a new hookup socket

I bought this part from VW

Pic 3
Pic 4
Pic 5

As you can see it is a panel that incorporates the exact area that has rotted away inside plus the outer sill from the seam with the side panel down to the join with the inner sill VW Part Number 252-809-294 £90.41+vat. A bit pricey but at least it fits and isn't made of rippled JK value tinfoil.

Additionally I got a offside rear arch repair from Schofields (no.15 on link http://www.club80-90.co.uk/pages/downlo ... 08_cat.pdf" onclick="window.open(this.href);return false;)

Once I get the van back I'll post some after pics

Got my van back after it's repairs (pics taken in haste and in poor light)

Offside on the inside http://i174.photobucket.com/albums/w103 ... G_2465.jpg" onclick="window.open(this.href);return false;

Offside on the outside http://s174.photobucket.com/albums/w103 ... G_2461.jpg" onclick="window.open(this.href);return false;

[ThorAlex]

Just a quick question.

Would the sill parts from schofield be enough to fix this or would i need something more?

[nenenaiad]

Hi,

The photo shows an area of the van that acts as a jacking point, as well as part of the support for the rear suspension arm. It is therefore very important structurally.

The innermost part of the suspension bracket is supported by the outrigger, with the outermost part of the bracket relying on the plate in the inner sill to give it support. In your case it does not appear to have any, and I would think that what you do now depends upon what the rest of the inner sill looks like. In other words it may be more practical to replace the complete sill rather than patch the area described.

I do not know how things work in Norway, but if your vehicle is tested at a testing station, it would pay you to get their opinion now as they are the people you will have to satisfy following any work done. It may pay to ask them if they can do the work as then approval should be a foregone conclusion.

Schofields would I am sure be able to fabricate anything for you, but as I say investigate first.

Regards


Dave

[Cruz]

Schofields have no inner sills or anything to help other than an arch repair plate.

VW is the only place for inner sills. Left side still available from vw dealers, right side only available from germany vw-classicparts.de

[nenenaiad]

Hi,

I have spoken to Schofields this morning and they should be able to help you with either O/S or N/S Inner Sills.

Although one of the sides has gone out of production they are manufacturing a replacement.

Regards

Dave

[Cruz]

Good news because they told me last october that they had no plans to make their own inner sill.

Can only be good that the list of bits for our vans is getting bigger.

However the obselete o/s inner sill was only £90 delivered from http://www.vw-classicparts.de" onclick="window.open(this.href);return false; (see wiki unde main dealers) and that's a genuine bit for £30 less than schofields listed price

[mikey9]

The answers all lie here!!!
The man is a hero in my view - and his work is something else

http://www.benplace.com/bjp_travaux.htm

specifically here.......for your fridge panel - mine is being done in the next week or two (bodyshop)
http://www.benplace.com/87_dove_blue.htm

[DentedDevon]

Hi
Did this repair myself last year , inspired by http://www.rustbuster.nl/Bus_zijpaneel/index1.htm
Bought genuine VW outer sill panel (just over £100).
Furniture out , not as difficult as I thought.Removed old sill panel leaving as much as possoble of surrounding pannels .
Had to repair lip of inner sill before fitting new outer. Repaired bottom of side panel after sill was fitted.
http://i248.photobucket.com/albums/gg18 ... air010.jpg
http://i248.photobucket.com/albums/gg18 ... air013.jpg
http://i248.photobucket.com/albums/gg18 ... air017.jpg
http://i248.photobucket.com/albums/gg18 ... air018.jpg
IMHO best to use original panels where available. Perfect fit, plus retains original structure .

[dugcati]

Richard - how did you repair the main body panel to the sill? - when I did this to mine I ended up doing this.....



then this........


along with a repair to both front and rear arches and that was after replacing the inner AND outer sills!

[DentedDevon]

WOW ! Looks like you had some challenge there !
I only needed to repair the bottom of the side panel below the fridge vent and to the rear of the vent.
I have a home made folder that will take sections up to about 15" long.
I made 2 sections ,1 about 3" deep and 1 about 1.5" deep. Seam welded to bottom of the side panel and plug welded the flange I folded on them to the top of the sill, as per original construction.

[pmulcahy]

What looked like a bit of filler turned out to be...

http://www.flickr.com/photos/avgas" onclick="window.open(this.href);return false;

It took me long enough to get two pairs of socks and some expanding foam out.

[dugcati]

it feels sooo good to see someone else with the rot I found on mine!... there really is only one way to sort it out and thats to rip the lot out and start over