what lies beneath part 2 updated

[colin944]

http://s1081.photobucket.com/albums/j348/colin944/sills%20p2/

I have been making templates. I painted all the inner sill with a zinc primmer,and then I started making templates for the sill fitment.If anyone has any images of the inner sill and particularly the bits between the inner sill and the intermediate pannel I would be very grateful to see them.

 

[JM1962]

Are you doing anything with the suspension mounting point, it looks pretty flimsy in the picture.

 

[FistsOfHam]

Looking good so far just don't forget to remake the drainage hole at the back of the sill. Somebody has done a similar repair on one of mine in the past but didn't remake that hole so it's just built up water and rusted away again.

 

[colin944]

The suspension mounting point will be re made in new 1.5 mm steel that will be stronger than the origional.The drain points will all be put back as well.It's just the early stages of the rebuild of this side I will probs be at it for about a month or so.The biggest advantage of doing things yourself is that you can spend alot of time making bits and getting the finnished product to be as goood if not better than stock.There is no harm in putting extra strengh into these areas, and of course when you are finnished you know exactly what has been done.More photo's as I go along.

 

[loc944]

Hi Colin, didn't make it down to see you this weekend, just as well as it looks like you were on a role. I spent yesterday morning making cardboard templates of lower rear quarter panel, outer cill and bottom of front wing. I then marked up what I wantd to cut out. This is on the better side and it appears only requires some small repairs. Then I took a deep breathe and got the grinder out starting at the join between cill and rear quarter and cut out a square about 4*3'' enough to see inner cill and appart from very light surface rust seem fine ( unlike other side which I had an incident with a wrongly positioned jack) Keep up the good work I I'll catch up soon. Alan.

 

[barks944]

Great work, lots of pics please its nice too see whats inside!

 

[colin944]

Hi all. I have started to cut out the floor.So far I have drilled out the spot welds along the inner sill and across the top of the box section in the floor. I then cut through the floor over the box section in order to give an invisible join from under the car. I then drilled the spot welds on the door pillar in order to gain access to the front end of the intermediate panel between the inner and outer sills. You can buy this panel but I am going to made it out of 1.5mm sheet and then run a couple of indents into it using the bead roller to give it strength I think this will be stronger than the standard part.I am not going to replace the jack points on the floor as I feel these are just crud traps so I will make extra strong sections across the floor and sill edges in order to be able to lift the car safely without causing damage to the floor. The jack piont are where the floor corrosion started in the first place as the car had been lifted using them and had split the underseal and bent the floor letting water and crud in.Please follow the link below to see what I have done so far.More photo's and comentary to follow as I get more done. [link=http://s1081.photobucket.com/albums/j348/colin944/sills%20and%20floor%20p3/]http://s1081.photobucket.com/albums/j348/colin944/sills%20and%20floor%20p3/[/link]