Re: inner sill
Posted: 28 Jul 2010, 18:07
I think I follow - yes you end up plug welding, when doing this you need to be certain your getting fusion with the steel in the bottom of the hole as often people just plug up the upper hole and never really bite into the steel underneath.
I also ran stitch welds along the edge of the inner sill to floor and again on the outer sill to floor/inner sill... looking back at my pics I'm a bit miffed as it looks like I covered up a rotten sill on the offside which was not the case - I just missed taking pics of the old sill removed/van with no sill!
Be aware that if your going to this extent rebuild the bottom of the b-pillar jacking point properly and also as I did rebuild/repair the c-post next to the back wheels
This was the b-pillar as I found it
note how the line of the pillar disappears at the bottom of the van....
Which was hiding this....
...after the rot had been hacked off I did a transplant of a complete good inner sill and a lower inner section from another van... (this is the part I missed photographing!)
To give you an idea of what the offside sill looked like.. this is the nearside sill after it was hacked off!....
As for the C-pillar by the rear wheel I had to remove the whole bottom section:-
... and again graft in another good piece from a donor van along with a stiffening plate over the box section join
From a non technical persons perspective it's quite scary that this....
which didn't look too drastic on the surface
needed this doing to it....
once I started digging - that said being a welder/fabricator in a past life said I knew what I was going to find hence the before pics!
I also ran stitch welds along the edge of the inner sill to floor and again on the outer sill to floor/inner sill... looking back at my pics I'm a bit miffed as it looks like I covered up a rotten sill on the offside which was not the case - I just missed taking pics of the old sill removed/van with no sill!
Be aware that if your going to this extent rebuild the bottom of the b-pillar jacking point properly and also as I did rebuild/repair the c-post next to the back wheels
This was the b-pillar as I found it
note how the line of the pillar disappears at the bottom of the van....
Which was hiding this....
...after the rot had been hacked off I did a transplant of a complete good inner sill and a lower inner section from another van... (this is the part I missed photographing!)
To give you an idea of what the offside sill looked like.. this is the nearside sill after it was hacked off!....
As for the C-pillar by the rear wheel I had to remove the whole bottom section:-
... and again graft in another good piece from a donor van along with a stiffening plate over the box section join
From a non technical persons perspective it's quite scary that this....
which didn't look too drastic on the surface
needed this doing to it....
once I started digging - that said being a welder/fabricator in a past life said I knew what I was going to find hence the before pics!
