Offside lower outer sill replacement

[orangebooboobearcrew]

Hello everyone,

After the van being off the road for the last 12 months due to various rot issues that need sorting for the MOT, I decided to have a go myself and bought a MIG welder a few months ago (Clarke 151).

I've never welded before but been doing loads of reading on here (especially metalmicky's exploits) plus on the migweldingforum and have got a couple of mates that can weld and have offered loads of advice. Will be doing loads of practicing in the garage when I can clear some space.

I have bought the main panels I reckon I need (so far anyway! ) and just need either a break in the weather (yeah, right ) or to find a unit we can rent out for a few weeks while I do it.

My question is, having done as much reading as i can find on here and Google, how do I weld the lower outer sill panel I bought from Schofield's? I have the short panel from the first horizontal seem down (will try and post a pic later when I can work out my new iphone ).

All of the posts I can find are for fitting the taller panel that goes up to the swage line but our van is solid above the seam and the floor is all ok, (I have already removed the interior), so I didn't want to chop out more than I have to.

I can see I need to puddle / plug weld along the bottom edge which is fine but how do I weld / attach the rest - top of panel / sides?

Also, to remove old panels with spot welds, is it best to use a spot weld drill then separate the panel or to grind the spots out?

Thanks for any help...

Chris

[Plasticman]

take some pickies of the areas inside and out please
mm

[orangebooboobearcrew]

oakley dokley...

[CovKid]

One way of doing it:

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

You could use all or some of the lower panel or even have a fold put in if yours doesn't have one. Either way, the pics should help you get an idea of the construction. Metalmick8y will, I'm sure, throw some ideas into the mix to help you along.

[orangebooboobearcrew]

Thanks guys...I had already read that thread but it doesn't quite match what I am trying to do

A pic speaks a thousand words...

[/URL[URL=http://s509.photobucket.com/user/christianfisher_2008/media/Mobile%20Uploads/2014-02/94618828-D4D3-410E-ACCE-E1A51DD81581.jpg.html]][/img]

[orangebooboobearcrew]

[img][IMG]http://i509.photobucket.com/albums/s331/christianfisher_2008/Mobile%20Uploads/2014-02/8BE3841A-AA98-49CA-B26C-99A3649D63BE.jpg[/img][/img]

[orangebooboobearcrew]

I'll try that again...

[Plasticman]

I'm on the phone so to be breif,there is solid rot there and the lower part of the fridge panel is rotten so is the floor closure,
mm

[orangebooboobearcrew]

Bugger. So does that mean I have bought the wrong panel?

What would you suggest in terms of repairs required and panels needed?

Thanks,

Chris

[Plasticman]

Will reply from the big screen this eve after tea

[Plasticman]

hey all is not lost,
i depends on how well you want to do the repair ?
you can cut the rotten sill of and weld the new one to the bottom of the inner sill and weld the top edge in the seam itself like i see very often or
you can cut that old sill off and obtain the full over panel that fits over the crap and weld it on, it will look better and keep the test man happy and is cheap and easy to do or
you remove the sill and if you look at the floor inside and see all that rust ,well thatr is right through the 3 layers of metal you have there,
way to do it if you want it cutting out is how i do them and if you have the over sill then cut it short and fold a lip on it and your sorted.
end of the day its down to your ability/pocket and how long you intend to keep the van
mm

[CovKid]

When I came to do mine I concluded that the seam was just a rust trap and I couldn't see the point in trying to reconstruct what was clearly an inherent weak spot for tin worm. Thats why I cut higher, spent time grinding out the rot from floor edge (which believe me, yours will have) and did the whole lot, welding up to next line. In the end it was quicker/simpler to do and no one has ever noticed the lack of horizontal seam.

You could try and reconstruct it all but its a lot of effort just to put back a seam that will almost certainly rust out again. Once you've closed it, you can re-tack floor to that panel (or even use a modern panel adhesive), or as I did, leave a gap. I keep my gas bottle there and if I did have a leak, it has an easy route out.

[orangebooboobearcrew]

Ok - thanks a lot guys...

Want to do as proper a job as possible as planning to keep the van as long as the bank manager lets me - I don't do bodging. My skills are limited at the moment but not afraid to have a go.

Think I will have a go at chopping old one out first then see how bad it is underneath before I decide what option to go for.

Your help is much appreciated - thank you.

Chris

[Plasticman]

the way i do them is very easy, just takes time and you need to use care, if it helps i occasionally make and supply the inner closures and a panel for the bit you will chop out if your doing it right, it is then fairly easy to do with a mig and most of the welds are spot/puddle welding so you will be fine
mm

[orangebooboobearcrew]

Thanks Metalmickey.

Yes, would indeed be interested in those panels if you did have some. All for doing it right...

I might need a hand on here though as I work through it to make sure I do it right...

Thanks again, Chris