replacing the n/s sill

[glyn]

How the hell do i change the nearside sill on my 1983 T25, i've changed the all the door skins but now i've got to the sill i'm kinda scratching my head. It looks like the complete sill has to drop down and pull forward but the bottom of the door pillar is in the way, so far i have got rid of all the spot welds in the gully of the sliding door and underneath but now i'm stuck because the sill is attached to the chassis outrigger which prevents it dropping down to remove it. Any advice would be very handy otherwise its gonna be the grinder and the super glue.

[dugcati]

Which sill are you looking to remove - the inner or the outer?

[glyn]

I need to do both, i've bought replacements from JK which are in fact genuine VW parts. Have you done one of these yourself?the more i look at it the more impossible it looks, but it's the last part of the exterior i have to do(save the best till last)before tackling the interior.

[dugcati]

It's a hell of a job Glyn! one that requires LOT's of work and hacking into your pride an joy..see my photobucket gallery of what I had to go through with mine once I started chopping out rotten sills - both sides of mine needed doing so I got it X2!

http://s62.photobucket.com/albums/h101/dugcati/t25/" onclick="window.open(this.href);return false;
password is club8090 (I think!) an its from about page 3 or 4 onwards.....

[glyn]

Thanks Doug, jeeeeez that looks a nightmare but i've got no choice, i'm going to tackle it tomorrow. I should have done the sill first instead of putting it off because now i've got to hack into the rear arch which i spent a day making good, bugger.
I really appreciate your help, i'll let you know how i get on.

[dugcati]

oh no! thats allways the way - hacking into something you previously sorted out! Where are you based? there could be someone close by who maybe able to help

Be aware that you can patch up the sills quite a bit - I opted to replace mine as I intend to keep the van and they had been patched over patches several times already

[glyn]

I'm in Southern Ireland, the sill has gone at both ends and like you i intend to keep the van so i may as well do it right now, i may regret saying that this time tomorrow.

[glyn]

Well its off and my god what an nightmare and the when i came to fit the new one i realised i hadn't ordered the complete sill so the job is back on hold for a few days, but at least its off.

[dugcati]

it gets easier after the first cut! - just don't get carried away and chop the whole van up
Post up some pics of your work as you go - it helps you see how far you've come with the work - allows others to pat you on the back and also give those who would like to try it but are unsure a visual reference of what is involved

[glyn]

Well the sill is on but i didn't realise that you couldn't get the replacement part that the sliding door slides on so i've had to make one up which took ages.A few finishing touches tomorrow and it will be done thank god, i have been taking photos as i go so i'll stick 'em on when its done so you can see my amazing welding(not) but it aint fell off yet.
I think its fair to say i'll NEVER do one of these bloody sills again.

[Plasticman]

Wherebouts are you in the south?
mike

[glyn]

I'm near Bandon, Co.Cork.

[Plasticman]

I come over at least once a year for a month or so , will try this next trip to meet up with as many as i can over there.
happy butchering with the sills
mike

[dugcati]

Well the sill is on but i didn't realise that you couldn't get the replacement part that the sliding door slides on so i've had to make one up which took ages.A few finishing touches tomorrow and it will be done thank god, i have been taking photos as i go so i'll stick 'em on when its done so you can see my amazing welding(not) but it aint fell off yet.
I think its fair to say i'll NEVER do one of these bloody sills again.

hehehe well think of it this way - they seem to last around 25 years on these vans so unless you buy another van that needs doing you should be safe for a good while!

have you taken any pics? would like to see your work and also allow folk on 8090 to give you a virtual pat on the back for your efforts