Replacing inner sills

[Plasticman]

Are you taking the whole of the o/s sill? the one we see in the pickies?
mike

[fidget]

Yes mike was just clamped on for the pics

[fidget]

Right i was trying to post from me phone earlier and after re-reading what I put It didnt make much sense.

What I was trying to ask is , as im drilling through the outer sill so I can puddle weld to the flange on the inner sill. Is there a mot requirement for the spacing of the welds?

cheers

James

[Plasticman]

oh well I pm'd you
mike

[fidget]

Last piece of the outer sill jigsaw got welded in today



not perfect , got a bit of a bulge in the middle. may try banging this out from inside



this corner pulled up a bit more on clamping so looks a bit better



bit that will be seen is lined up so what the hell Im happy

Rain stopped play , then cleared up so seam seeled all the inside sill and the rear arch. had a tidy up and swept out the van . Then procceded to shut the wife in the tailgate, she aint happy .

James

[jimpainter]

Done a good job there mate. Well done

[fidget]

Cheers Jim

finally feels like ive broke the back of it now, no where near finished but one big job out the way

James

[Plasticman]

looking well sorted there james
mike

[fidget]

Despite the weathers best efforts to wash me and the van down the hill the inner sill is now attached to the floor with shiney new metal . Opened the tailgate threw me tarpaulin over the back end lobbed on some slabs instant welding shelter .

To save a bit of time I made up the new flange sections one night this week at work , which was fun as we have got a load of swampys living in a tent in the woods next to our yard , dont think they where impressed with me making a racket at half 9 on thursday night.

I decided to use the depression in the floor as a means of locating the new metal . so cut out the old metal about 6mm ish from the edge (thats 1/4" for metalmick8y)




this next picture shows how rusty it had got , its virtually paper thin in places



after the b-post episode I thought it would be a good idea to tack it all in first





One marathon welding session later



I got way to much heat into the new metal and when it came to welding to the inner sill I had to use a bit of wood wedged up against the inner bodywork to push it all together







I wanted to close of the hole above the front crossmember to but the rain stopped for a bit so I managed to get everything dried out and packed up before it started again.

Just the panels that join the floor to the outer sill/tall side panel to make and the sill saga is done

James

[jimpainter]

[pmoc_2001]

Fidget,

Thanks for the pics. I'm about where you are with my outer sill replacement. Your pictures have given me some inspiration with regards to preparing the floor lip with the aim of welding in a plate to cover the gap and joining it to the sill. I have 2 questions though.

How did you find welding to the rusty floor lip?
How will you weld in the section to the sill? Will you seam weld to the new floor lip and then to the sill?

[fidget]

Hi pmoc_2001

There was no rust to weld to , all of the old metal that welded to the inner sill was rusted so it was all cut out. I replaced the metal from the front cross member all the way back to the start of the c-post . In the second picture the surface rust has just crept back to the start of the depression , a quick blast with the wire brush in the drill and it was back to good metal.

the panels that will lay on the top of the floor and the lip/flange of the outer sill and the tall side panel will be puddle welded in place and seam welded where they contact with the b + c posts as they were originally (albeit spot welded from the factory)

cheers

James

[fidget]

Well the kiKds are at a party , and its raining again so Ive knocked some mock up repair panels from ply and cardboard, pretty good fit , get them transferred to steel in the week at work .








James

[Plasticman]

good stuff, dont forget bto drill spot holes and just tack through evry 6" (150mm to you)on the outers no need for more than 40mm ish for nthe rest of the spacing
M

[DavidPallister]

Hi James

I've got the B post outer repair panels from Schofields, almost ready to fit them, and was wondering if you had made any drain holes to let any moisure / condensation out from the base of the B post?

Dave