Does this need welding or can it be left? Advice appreciated

[thehosepipe]

Having removed the interior of my camper I found rust on the side of the floor, furthest from the sliding door. This had started inside the van and eaten through the floor along that side. The sill is solid, untouched, had been well waxoiled. But the rot has eaten away right up to the outer panel, but not quite touched the panel.



There is a small section of floor that's rotted beyond the sill so can see road through it.



Obviously I need to get a section of floor welded in, but to weld a section in covering the whole sill would require welding to the outer sill facing as the internal metalwork is mostly gone. That would probably damage the paint and need a respray of that section.

My question is this. Is the floor integral to strengthening the sill? I ask this because I could

1 get the whole rusty missing part welded, but that likely requires a respray of the outer sill facing

2 get a smaller floor section covering only the part where you can see the ground, but not 'close off' the sill. Ie not have the extra section of floor be welded to the outer sill.

So any advice welcome. Is this bit of floor structural or can I get away with option two?

Thanks!

[DentedDevon]

It needs mending! The outer sill and the top part that has rotted away are one piece. The side panel has a lip which is spot welded to the top of the sill.
I replaced one a few years ago when the original sill was still available.
Looks like this



I think the repair panels they make are for the outside of the sill and a few inches of the side panel, which you say is OK
So , unless there is a repair panel now , you are going to have to make a repair plate for it.
Try searching for "sill repair" or "off side sill" its a common problem and has been discussed plenty.

[thehosepipe]

Thanks Richard. I was afraid that may be the case. Ah well, at least the whole sill doesn't need doing, I think I better Buy a replacement sill.

[DentedDevon]

Sorry I didnt explain very well , as far as I know you cannot get a ready made repair panel for the top of the sill/floor. Not for RH drive anyway. Availability for LH drive may be better?
I dont think the original complete outer sill in my picture is available any more, in RH or LH drive.

I use http://www.vagcat.com to find original part numbers. (you need to register for full access)
You can then search for the parts on Classic VW parts http://www.vwheritage.com/vw_act_vwclas ... try_GB.htm
Or search on Ebay or google them depending on what you are looking for.

[Plasticman]

page 3 onwards
http://forum.club8090.co.uk/viewtopic.p ... lack+of+it" onclick="window.open(this.href);return false;
or if you dont want to do quite as tall a bit then
page 15 onwards
http://forum.club8090.co.uk/viewtopic.php?f=38&t=93497" onclick="window.open(this.href);return false;
your panal bottom is also complketely shot, so dont waste time, cut it off, lower outer sill is available, top closure plate you make and lower part of middle panal you make ,
im doing another of these this coming week , maybe i should make a few spare sidepanal lowers and closure panals.??
you can buy the outer wrap over sill and add a lip to it but its not the most satisfactory way of doing it, but it will do the job
mm

[thehosepipe]

your panal bottom is also complketely shot, so dont waste time, cut it off, lower outer sill is available, top closure plate you make and lower part of middle panal you make ,
im doing another of these this coming week , maybe i should make a few spare sidepanal lowers and closure panals.??
you can buy the outer wrap over sill and add a lip to it but its not the most satisfactory way of doing it, but it will do the job

By the panel bottom you mean the lower lip of the outer skin, not the bottom of the sill? If so yes there is little left of it. Presumably then you mean to replace the lower part of the panel and its lip, the outer sill (which is welded to the panel lip) and the triangular section to close the box? Is that right?

I would certainly be interested in the parts if you make them!

There is also some rot at the bottom of the B pillar. If the sill has to come off that would be accessible. What's the advice there?

Thanks

[thehosepipe]

The bottom of the b pillar

[boatbuilder]

I got away lightly with mine..... only had to make up the closing top piece.
http://forum.club8090.co.uk/viewtopic.p ... &start=105" onclick="window.open(this.href);return false;

[Plasticman]

have a read through the first link i gave you,,but it really depends on how far the corrosion has gone , either way you will have to remove whats perished and when you can see the area then post up a picky or two
if I decide to make up the parts i will know after/during the weekend and will pm you
mm
ah yes , sorry but that really does need removing, Ican do the inner support part for the front jp's, but will be able to advise better when its all on show,or not as the case may be

[boatbuilder]

The bottom of the b pillar

A left hand drive van then...

[thehosepipe]

have a read through the first link i gave you,,but it really depends on how far the corrosion has gone , either way you will have to remove whats perished and when you can see the area then post up a picky or two
if I decide to make up the parts i will know after/during the weekend and will pm you
mm
ah yes , sorry but that really does need removing, Ican do the inner support part for the front jp's, but will be able to advise better when its all on show,or not as the case may be

Ive read it, in fact was doing it when I first posted. Bodywork is new to me though so struggling to understand it, or rather relate it to what I need to do.

Much of the lip on the panel has perished but the panel is good, the rot barely touched it. I was thinking it makes sense to weld a new lip to it from inside? Seems a shame to cut away so much good panel just because of the lip.

So the b pillar reaches down to the jacking point. I hadn't realised its significance. Only way to get to it is to remove what's left of my larger closure panel and sort it from the inside right? Rather than cutting a chunk out of the outer sill. If so I will remove that piece of panel tomorrow and post more pics.

Very grateful to you all for the help so far!

Al

[thehosepipe]

Yes should have said. Lhd van, 1986.

[Plasticman]

well I know what you mean about the panal itselfd being good but just adding a lip will not sort it out , you have it exposed so you really do need to remove the bottom and make /get a new bit,
The b post bottom is in effect the jp or should i say the support i make to fit to the inside welds to the external socket and carries the load up into the b post if that makes sense , you really should open it up but picks when yopu get the definate rot removed and then we can elaborate.
mm

[CovKid]

http://wiki.club8090.co.uk/index.php/Ar ... outer_sill" onclick="window.open(this.href);return false;

[Plasticman]

nowt like being "spoilt for choice"
mm