Sill replacement

Hi all having to sort the sills ready for an MOT. I have decided to replace like for like rather than going box section like I did last time. Got new inner and outer sill sections from YRM just wondering how to deal with the little upstand that the door rubber connects to? Do I try and cut round it to reattach to new sections or should I make up a new piece??
Thanks all

moorsman61 said:

Hi all having to sort the sills ready for an MOT. I have decided to replace like for like rather than going box section like I did last time. Got new inner and outer sill sections from YRM just wondering how to deal with the little upstand that the door rubber connects to? Do I try and cut round it to reattach to new sections or should I make up a new piece??
Thanks all

Click to expand...

Leave the original & cut underneath it if its got enough good metal to weld to.

Yes that part is sound rest of it's poor lol. Is it just spot welded?

moorsman61 said:

Yes that part is sound rest of it's poor lol. Is it just spot welded?

Click to expand...

Not sure pal ive never tried to remove it every disco ive done the seal rail has been solid.

Out of curiosity, why don't you want to use the goto box section replacement?

Jayridium said:

Out of curiosity, why don't you want to use the goto box section replacement?

Click to expand...

Well that's what I did with my 3 door but it turned into an absolute nightmare trying to weld thin stuff onto the heavy box section. Also this vehicle spends 90% of its life on tarmac so no real need for jacking off the sills.

Fair enough. When I did our 300tdi with box, I didn't find it that bad, I started the arc on the heavy box, and worked the puddle up to dissolve the body's thin metal with the molten metal from the weld pool. So I wasn't playing the arc onto the body, and trying to balance between settings that melted box section without burning through the thinner bodywork. I also used the much maligned flux cored wire as I find it flows better

Unfortunately I had set off in a borrowed workshop with someone else's welder etc. As I said it was a nightmare