Club 80-90 Forums

aye well they have their specific places,you just need an owner brave enough to allow it to be revealed
i will look back through the sunnivagon to refresh the inner sill
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Well now .
i have this

just left with 2 sheathes with multi wires in them that go to the front so ..........................i have half a plan
been out to buy a new mini cutter

i works

1/32nd nozzle so great for detail cuttings
this is the underside of the support piece that is not present on the std van

a little despotting of the old inner sill


undone

im leaving the very top as the sill lip is under the floor and cannot practically be removed and as its very solid there is no need to make work.i will cut out as needed .

you can see the insides of the rear member are fine so very good to weld the new sill to
nearly all rot cut out

these are the spots on the join between the rear wing and center panel, rear wing sanwiched between the centre and C pillar of course

and as always .......

watching
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this is hardcore and very interesting to see

well you cant just join a part it has to be reconstructed to put the strength back where it belongs which is why its easiest to remake in the way it was originally built
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wires going to the front will be throttle pedal, OBD port, immob ect ect Fair few wires there too...
The extra metal work, is it 16" specific or just syncro? 'tis weird seeing the van cut up like that, but i can see some original metalwork without rust!! Great how you pick it apart, gives you a real sense how it all fits together.

this

I hope your listening to the tips he's giving you?

does he? have a name
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Monke (you say the e )

Maybe i could change the name to metalmonk8y?

I have just caught back up with this. Brilliant and again somehow reassuring that when the time comes all will be well. As you say Mike bravery needed. Well done fellas

Well, front woes
sealant of the outrigger, note the marks where its welded from the rear

this shows the seam which is the top of the outrigger,the panel above is sort of the rear of the battery box

its been played with in here before

old repair to left, the inner baser of the B post is shot.rotten.scrap malkes my life easier, just chop it out and make new

all this is rubbish and filler etc

note the JP support bracket, shows just how well built these vans were as it still worked, i will make a drawing of this part as ive been asked for it a few times

ive cut the front of the outrigger away to give better access to the hot spanner

self explanatory



now just tidying up the area and we place the new sill

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Amazing, Love seeing the detailed pics

The weld on that front outrigger in the first pic, is that from the factory?

It is yes

just had a look back through the last few pages, man i have a rusty van Quite shocking really, if i was looking at this as a prospective buyer of a T3, i'd be very nervous. As to the untrained eye, it didn't look too bad..

Well chopping out time again,
the front here is self explanatory,anyway we have to remember that when built the inner sill went on before all the closures and floor sections etc, now you can just chop what you see and be done with it but if you want to fit it nicely then this is my take on it,

the long bit is the remains of the lip of the old inner sill and as you casn see it goes under the outrigger top and is spotted, well not for much longer

drillings, i have crudely folded the closure out the way to give access, soon reweld it though

im jumping forward a bit here , but forgot a picky with it all of so this has the new sill temp held up there to show

rear end is roughly in place

i have left a ssmall part and its respective lip as this is fixed same as front end and im not going to rip out all the inners just for this as the metal is excellent and will weld up nicely.
you can see the tab at the rear, it confirms that i need to go in a few mm and back the same amount
this is the inside/underside


the lip where im holding it with the grips will be removed as its not a good way to do it even though it is how vw did, i have a better method as used before and will explain as i go along

most of it gone

this shows roughly whats inside the outrigger,it will soon be all fixed together

this side outrigger has been used to jack the van up so will straighten it before welding up

these are in a bit of odd order as failed to label the list
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