Ajitvagon

[LittleMissSunshine]

Yes, but it looks wierd not being on my drive!

[DustyBiscuit]

Swap "lee" for "more". Stoopid predictive text!!!

[LittleMissSunshine]

Thanks Dusty, your van looks like it will be awesome!

[lloydy]

i think the ladies and myself can accept a few thread diversifications, bring on the best of them
mm

you'll have to wait though, don't often take pics of the bad bits i have a cab step to cab door shut line to die for....

[LittleMissSunshine]

I can wait

[Plasticman]

Well so can I...
had a case of one fwd and 2 back ,
when i had the blaster out i gave the edge of the sill a sweep over, and now I have this to remove

only just welded it on but found a few small holes appeared behind the new bit, dont know how i missed them but anyhows ,if I left it then in a year or so they would appear and whilst not a failure item, it would be a bit sloppy and embarrasing so

out / off with it
folded up a nice bit od 16g (1.5mm) and clamped the sill on and offered it upo to trial fit


i made it a touch wider to allow for the usual sill problems in that they made them too short....
ran the mig down it , as i couldnt get the tip close as i like i wound it up and the gas and did it from a good 1/2' away....

seemed to penetrate ok

and the sill fits snug in there


weld it all up later
mm

[lloydy]

ok, two pics. I won't hijack to much!
cab step, hmm don't think there is meant to be a gap there? can see daylight from inside, gets interesting when wading!

By syncrolloydy at 2012-09-15
and my pretend seam, he did not use a ruler!

By syncrolloydy at 2012-09-15

[DustyBiscuit]

The pretend seam is class!

[lloydy]

what makes it funnier is that there is a brand new panel under there!

[Plasticman]

looks a pig, did they buckle it badly when welding it to the arch...shudder the thought
mm

[lloydy]

panel was lapped rather than butted together, so the painter fillered to make it level. I'm of on hols the 28th oct for a week, thinking of touring up your kinda way with the kids, you around for a visit?

[Plasticman]

You can......

Well sorted the sill out today instead of being out and about in the sun....
painted the inside of the inner sill so all the hard work is done and the nice bit remaking starts with it

what i have done is to confirm an as near perfect fit for the outer sill to the inner and the b and c post, this now sorted i have made a lower repair piece for the side panal, pickies may be in a disjointed order....
this is the outer sill clamped on and the repair piece being trial fitted

same t'other end

after making the top bit fit everything else I drilled the panals ready for spotting

this from the face side, giving a good tight seam

fitted to the side of the van ready for welding

usual fasteners to hold the panal over the joddled lip

starting another page..,.......

[Plasticman]

Well started welding up


there are several ways I do these panals and the difference depends on the extent of the rot and a few other areas,anyhow its vitaly important to make sure you start with the outer sill being a correct fit to the inner and not pulled in and bowed as this in turn will cause the side panal to deform(not straight forward as all the pattern ones are misfolded and dont have the correct lip profile)
inside

just the sill closer panal to reweld to this new metal
the ends have been cut this way to allow gassing and will be ground back .its not the neatest weld but had to be done very quick so as to prevent warping


now done apart from a quick pass with the sander.

mm

[Plasticman]

well been distracted by a syncro for a couple of days ,
so started on the filler area,this is the start

havent got the tooling sorted yet for these so set about doing it the long way,by hand

we soon end up with

other side

so after folding the edges we now have a basic part ready for nudging into better shape

the basic shape is ok and it sort of fits the plastic shroud but i have to make it fit the van and the rest of this area before final adjustments


now the laborious job of getting it set up

little bits of removinhg metal until its right, this is from the other side , the 2 parts are not yet welded together

happy now so clamped ready to weld

now welded and had a light sand over

fit is acceptable

the castelations of the recess are not uniform which complicates matters and i didnt have an undameged one to hand so it took a bit more work that it should have, its made from about 1.3mm steel so should last out ok
mm

[DustyBiscuit]

That is beautiful! You're a wizard! )