Replacing inner sills

[fidget]

Hi Dave

I havent put any holes in as yet , its something I keep thinking I should do. Also maybe put some in the sill too. If anybody else has got any opinions if this is a good idea or not , i'd love to her them

James

[Plasticman]

Have a look back at how I did mine http://i42.photobucket.com/albums/e308/ ... G_3663.jpg" onclick="window.open(this.href);return false;
http://i42.photobucket.com/albums/e308/ ... G_3665.jpg" onclick="window.open(this.href);return false;
but it would be neatest and easiest to drill and spot through and fairly replicates the original , joddle the front edge where it joins the very front plate so it sits flush when done, then a coat of seam sealer along the joins and your done, are you bothering putting the hole back in the bottom of your B post,
soon be done and on the road..
mike

[fidget]

Is it worth putting drain holes in the b-post base and the lowest point of the inner sill then mike ??

I havent closed off the hole in the side of the b-post yet if thats the one you mean , but I think I will as its position is right where muck from the front wheels is going to get flung.

Didnt get the panels made tonight as the pikey fairys paid a visit sunday night and robbed all the titanium from the metal store, so spent most of the night welding the bolts on the metal store so their magic pi-keys cant undo em again.

James

[pmoc_2001]

Have a look back at how I did mine http://i42.photobucket.com/albums/e308/ ... G_3663.jpg" onclick="window.open(this.href);return false;
http://i42.photobucket.com/albums/e308/ ... G_3665.jpg" onclick="window.open(this.href);return false;
but it would be neatest and easiest to drill and spot through and fairly replicates the original , joddle the front edge where it joins the very front plate so it sits flush when done, then a coat of seam sealer along the joins and your done, are you bothering putting the hole back in the bottom of your B post,
soon be done and on the road..
mike

I'm a bit worried now as I have not got the flange along the length of the panel to puddle weld to in order to fill in the gap. I guess this means I will have to butt the floor right up to the side and fillet weld

[Plasticman]

do this then
http://i42.photobucket.com/albums/e308/ ... G_3367.jpg" onclick="window.open(this.href);return false;
http://i42.photobucket.com/albums/e308/ ... G_3372.jpg" onclick="window.open(this.href);return false;
very quick dabs with the mig to give a lip, keep it cool, this welding is a bit rough but I didnt use a mask I just closed my eyes and tacked, (quicker) well that was one reason
you will find it easier to tack a piece on like this, and when done you can weld your floor closer over it and take your time as no heat distortion to your nice new outer panal.
mike

[fidget]

Well its all over , the sill is done and dusted

Dispite last minute panic getting a new bottle of gas and running out of wire with just 9 plug welds left to do . The sill is finished bar a dab of seam sealer, paint and under-seal

Managed to cobble together some floor sections at work this week, also managed to re-use the floor section I cut out above the cross-member. So that saved a lot of time.



floor sections going in



I had to make the long section in 2 pieces as my sheet of metal wasnt long enough







Side panel fits which is nice



all seam sealed up waiting for paint



and to put a face to a forum ID heres me looking suitable smug after a hard days toil.



Still more welding to do but its not really relevant to the sill replacement so the thread has come to productive end .

Ive probably bored you all with me ramblings anyway, but if its of use to somebody then Ive achieved at least something.

I have to admit to feeling rather good as 6 months ago I'd all but given up. Big thanks to metalmick8ey and everybody else whos helped.

I am now going to get drunk

James

[jimpainter]

Thats a great job mate. Well done

The big question though is how many times did you have to set the timer on the camera to get a pic of you looking smug with a cool pose.

[Plasticman]

Agreed, a brilliant job and well done, never thought of that but maybe




















an accomplice
M

[jimpainter]

Surely not, if there was an accomplice we would have had pics of him working

[fidget]

only accomplice is the wife

I'd finished clearing up and the kids where down for a sleep so me and the missis just spent bout an hour just sat in the van realising the blooming thing might be done soon and her talking bout curtains .

Bearing in mind my total aversion to cameras she did well to get to catch me even remotely happy .

James

[Plasticman]

youve got a good name, .looking at that picky you resemble someone than might well er fidgit a bit like get irritated a little
bit scary now as you may actually have to go out in it and maybe OMG stay out overnight.......
Now what sort of curtains are getting made, and what flooring and and.
M

[fidget]

Spot on mike fidget by name fidget by nature .

Bit scary now as theres no big job left for me to do and got nothing to occupy my time .

Ive got no Idea what the curtains are going to be like , foolishly I agreed to leave that to the missis .

Floor is going to be the old lino from me mum and dads old kitchen they were going to bin .

When I run out of welding wire the missis popped to halfords while she was out and about , had a quick nap in the van while I waited so technically Ive slept out in it .

still cant beleive I've done it

James

[Aidan]

nice job, and cracking thread, thanks for sharing, enjoy

[mm289]

Well done fidget, looks great, just about to do the same to Gunther (hopefully without all the B post repairs ) so all the info is greatly appreciated.

Enjoy

MM

[fidget]

Well heres a quick up-date

not been resting on me laurels but did have a break for a bit, a quick tug of the seat belt mount was all it took to pull it out so that was next on the list.
I'd pre-empted this and I had a panel from schofields ready to go in. Could of made one but time is at a premium now so cheated .

for once no dramas, re-placement went in with out a hitch. had a bit more surface rust so cut all out .



I lost last weekend cause it was me wedding anniver,sary, been working flat out after work every night this week to get the rear part of the front arch in , filled and primered before any rust could get its dirty claws in to me new seams. Started the welding last friday. Finally got it all primered tonight.



Bit streaky but primer was still drying. ten minutes later the heavens opened up so got it done just in time .

Start on the rear brakes and brake lines this weekend, anybody got brake lines from Vw heritage?? lot cheaper than justkampers just wondering if there was a reason why

cheers

James