Club 80-90 Forums

I have started making my way through the rust on my van but need some advice on a repair of the sill near the left hand front jacking point.

This is what it looks like now







The outer sill need replacing but it's behind the jacking point and chassis leg. My plan is to cut off the jacking point and end of the chassis leg for access, make the repair and weld them back on. This sounds drastic so wondering if there is an easier way and what the best approach is.

Thanks

Whitevanman

Have a look at MetalMickey's Gaswagon thread (his current one, shouldn't be far up or down the list from this thread), from page 20 on, he's just done this very same repair

have fun and post pickies inc skinned flesh
mm

Thanks (I think). Looks a bit awkward so we will see how I go. Will post pics but hoping to avoid the skinned flesh! Have ordered some 2mm plate in anticipation of the fun. Probably need b post repair and door seal channel as well at least.

Wvm

whats it like on the inside/floor area
mm

Floor looks OK so will go at it from underneath. Did a bit more cleaning up of the area - no worse than expected





Here it is with the shi*e cut out...







Made a small repair section for the sill / lower door slider panel as its otherwise OK



Started on a repair section for inner B post. Still needs fettling and seem to have lost any point of reference due to original having disintegrated. Need to look at some photos on here.



I hope to re-use the jp as I don't have the wherewithal to make one and will fabricate a new support bracket for the B-Post

Door seal shot so in the market for a replacement.

Happy with progress based on a few hours but could really do with a couple of days flat out to get this sorted

wvm

thats the way .cut the rot back to clean steel (also nicer to weld), the inner part of of the B post is fine, you dont have to make it shaped like the OE, also the inner support for this , have a look at my latest on lloyds and make it something like,buy the main jp as it will be worth it as its then good for a long long time.,
i have a brand new slider seal will pm you ( already did a week or so back)
mm

Made a bit of progress this afternoon

I welded up the inner B-Post repair. It was a pig to make because it also forms one half of the door seal channel


Also Waxoyled inside of sill whilst I had access and bought a fire extinguisher to put out burning Waxoyl from welding nearby.

Then made and welded in a sill repair section. I hate welding upside down





Nice and shiny new jacking point



Fabricated a support bracket



Welded in. Doesn't look to pretty but hopefully its strong enough as weight will be transferred to inner B post which is the main thing, not the outer skin. Struggling a bit on the thick stuff with my DIY welder.

your doing fine, youve got there, nice pickies as well ta
mm

Hi MM, I like your approach to re-attaching chassis leg to JP. Think I will copy that. Door Seal arrived OK

Wvm

Managed to make a bit more progress......

Chassis leg repair made from 2mm plate





Welded in with new jacking point





I was trying to avoid buying a b-post outer but did in the end as I couldn't create the swage line. I chopped it an used the top section to make the return and channel for the door seal



outer welded back on



Needs a skim of filler and the gap between the b-post and wing it to large but that will be filled with seam sealant and covered with the side planks anyway. At least its now sound.

I have won this battle but wonder if I am loosing the war as lots more to do

your doing fine and as your finding ,some things are a bit in the wrong place and shape and it can be frustrating to get it right but as you say its strong and fit for purpose, so onwards to the next area ??
mm

Thanks MM. I've also done the step and numerous small patches to that corner although nothing as involved as the jacking point. Will work my way across the middle as the tank is out and then tackle the offside front. For some reason the offside is in better nick. Perhaps puddles and mud next to the verge means the n/s gets a harder time?

wvm