Sill replacement

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moorsman61

moorsman61

Member
Posts
44
Location
Rievaulx north yorkshire
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.
 
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 🤷‍♂️
 
Hi, I'm looking at doing mine, the rear outer and bottom have gone on both sides. I wasn't sure on buying the repair panels as they are only 1.2mm but didn't want to replace the whole length with box section as it's seems alot more work and alot of welding (I've not welded in years) and was thinking about just replacing the rear sections, between rear door pillar and rear arch, with box and capping the end where the arch attached as that has rusted through too.
 

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ClanSmith said:
Hi, I'm looking at doing mine, the rear outer and bottom have gone on both sides. I wasn't sure on buying the repair panels as they are only 1.2mm but didn't want to replace the whole length with box section as it's seems alot more work and alot of welding (I've not welded in years) and was thinking about just replacing the rear sections, between rear door pillar and rear arch, with box and capping the end where the arch attached as that has rusted through too.
Click to expand...

You will regret only doing a section, cut it all off & do it properly. There is more prep than welding.
 
Just a heads up guys so you don’t get a nasty surprise but if your sills are rotted, check the centre/rear body mount just before the body arches up to the rear seats, if that’s rotted then you’ll most likely have to replace the corner of the rear floor too where it arches up to the seats. I did box section, had to do both sides of the floor too and replace 2 body mounts but weld all 4 back on as had to completely remove inner sill. Drill out any spots welds, pain in butt to do and a lot of work but do a proper job once, a poop job twice.

Also on welding the body section to the pillar bottoms I found I could push 20v 150A to get it all welding nicely together but the thinner metal I had to run a bead on the box first like the above then drop to 17v 120A and keep runnning over the bead right next to the thinner sill metal and it would heat up and incorporate it without blowing it. this may or may not work for you, you will have to test things. 2nd pic I had to grind off and start again lol.
 

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