Club 80-90 Forums

Hi,

Re - Outer sill - Offside.

On my T25 I have a tell tale line and bubbling which I would imagine is on the line of the outer sill.

Would this be the original outer sill, and if so I presume it is spot welded on at or near this joint ?

If so I presume it is removed from the outside ?

I have obtained as a repair panel the JK Sill and Lower side panel (RHD) J13898 which extends a few inches higher than the bubbling joint and also has no flanges at its ends.

Anybody who has been this way before got any thoughts or ideas.


Regards


Dave

A repair panel is supposed to do what it says on the tin by being big enough to cover an affected area usually when seams have long gone,,,, if it was a repair section it would a specific piece complete with edges/ flanges/ and be a direct replacement for an origonal panel section....
.......................................................................................................................................................................................................................................................


This has to be the biggest load of b ll cks I have written for some time.....


Regards


Fritz,,,,,,,,

Id be interested in this too. As far as i can see you need to cut out the panels.

Any pics of anyone whos done this?

Hi,

Thanks for your interest Stevep.

Here are the photos :-




I have attached two photographs above. The van I am talking about is the red one.

Having now had chance to compare the red van with another, it actually looks to me as though someone has filled the joint between the sill and the upper panel. They have done it very well and completed the process with a matching paint job.
I guess if someone had covered the joint up like this and its carried on corroding,this is what I would get.
(The gaping hole to the left is where I have removed the rear wheel arch ready for replacement. )

I have enclosed the picture of a white van I am comparing it with.Thats what I would have expected - some indication of seam.

Having found this I think I have to dig away at the bubbling joint on the red van to see what I will find, and then contemplate how or if I use the replacement panel.

Regards


Dave

I've got the same sort of thing going on with mine, i.e. filled over seams - I dread to think what's going on underneath. I don't have a garage so will have to do it outdoors when the weather's better (ha!) In the meantime, any updates on your progress would be very helpful (to me anyway)

I done mine just after buying the van and removing the interior. The lower panel around the fridge vent was a mess, as was the sill and the top close out panel, so i cut the whole lot out. Got the same sill/lower panel from JK, cut it to length, welded flanges to the b and c pillars, spot welded the new panel to the inner sill at the bottom, the flanges up the sides, then seamed welded it to the rest of the side panel above, then made a new top close out panel and spot welded that into place inside the van, then filled all around the panels with seam sealer inside and out, waxoyled inside the sill, hammerited inside the van and primered outside (haven't gotten around to spraying outside yet

Dave

Hi,

Thanks for that.

Curiously I have just parked alongside a Caravelle at the local B & Q and would you believe it, it was just like the red one, so there must be variations of how this is done, or perhaps it shows a repair panel I don't know.

I will gladly take photos of my progress both with the Rear Arch and the sill. Somebody will I am sure know why there is a variation, and if you do could you let us know.

Many Thanks

regards

Dave

This is a well used link on this forum

http://www.rustbuster.nl/Bus_zijpaneel/index1.htm" onclick="window.open(this.href);return false;

Although you are not intending on replacing the whole side panel , it is a useful link for getting your head around how it is all made up.

Interesting stuff, my van too doesnt have the seam, i only noticed it when the seam reappeared - splitting the two panels. A job for warmer weather. Keep us posted how you get on.

Ste.

With the JK panel, you loose the seam altogether as its all 1 panel. Better in a way as there's then no join to go rusty again, but it may set alarm bells ringing for a future purchaser as they might think that the seem has just been filled over
You can't win

Dave

try to access the inside before cutting the outside!
you may well find very big holes on the inside floor! , very common so you can prepare before you kill the van.

to do the job correctly remove any inside furnishings ie panels , cupboards , seat!

as well as preventing fire this allows ver good access to close the repair !

also when done paint the inside , then waxoyl to the max!

am just , right now , doing mine --- i may be wrong , but i think you are referring to the seam caused by the sill-top-close-out-panel , which was totally rotted on mine and i hope not to have to replace it , which would mean fixing a horizontal panel part way up the inside of my replacement panel ( which is about a foot deep, from top to lowest sill )
jaylo

This was how my van looked

Outside Pic 1

Inside Pic 2

As you can see over the last 25 years the lower outer sill panel has completely rotted thus making a gaping hole in the floor and the seam gape open where the lower outer sill meets the side panel. Sadly it also affected the inner sill very badly.

The van is currently in the workshop having the inner sill (bought from Germany, no UK stock), lower outer sill inc. inner floor area (VW UK) plus a piece made up to replace the side panel from the seam to the swage line with a new hole for a new hookup socket

I bought this part from VW

Pic 3
Pic 4
Pic 5

As you can see it is a panel that incorporates the exact area that has rotted away inside plus the outer sill from the seam with the side panel down to the join with the inner sill VW Part Number 252-809-294 £90.41+vat. A bit pricey but at least it fits and isn't made of rippled JK value tinfoil.

Additionally I got a offside rear arch repair from Schofields (no.15 on link http://www.club80-90.co.uk/pages/downlo ... 08_cat.pdf" onclick="window.open(this.href);return false;)

Once I get the van back I'll post some after pics

Great be interested to see the pics when you get it done. Are you doing any of the welding yourself, or getting a garage to do it? Ive just brought a mig welder to do the odd bit, if im any good!
Checked my seam today and it is there, just full of filler!

Would rather pay someone than make a pigs ear. False economy imo