Connect sill repair part 1, 2 , 3 showing before repair

[metalworker0]

its a lot worse than i thought ,

i first marked out part of the inner sill that i wanted to remove (the whole thing will be removed in stages) note- so you can sort it out in your head, which way up we are , welder is in the bottom right corner ..

[metalworker0]

this is part of the inner sill removed ..about 70 percent of it, old patches done last year by MOT garage - previews owner ..what you see on the outside is not what is on the inside - beware when buying !

[metalworker0]

had to remove even more ,,,because the rust was so extensive the red area is middle sill and tomorrows cut out work

[metalworker0]

looking down the middle sill (inner removed)..2.5n inches of this will be removed tomorrow, note: strait area at bottom of the picture is the flange for upper box section ..the middle sill (when its there) hangs down another inch below it.

[metalworker0]

cutaway - cross section area of front of the sill showing: outer , middle and inner .and old .reinforcement for jacking point (red arrow() ...all this will be chopped out later ..with new more substantial reinforcement put in its place the other end of the sill - the rear is even more complicated .

[metalworker0]

For clarity ..
chassis box varies in size ..smaller under the doors .
here's section where there isn't a door.

[metalworker0]

Showing extent of rot in middle sill, most of what is in red has rotted and gone - this is also the closing panel for the chassis box section...which is why on this side i have had to remove the entire inner sill to repair it......it's inaccessible and cannot be repaired properly otherwise!

The other side which i have already done ..wasn't that bad in the middle sill area ...so it's the kerb / passenger side that gets it ..

[metalworker0]

Had to cut more inner sill away to be able to take the middle sill out .

Long arrows show now open chassis box section, short arrows galvanising ground off .

I then shot blasted it.
wavy cut will be tidied up before welding

picture 1 is before blasting
picture 2 half way through blasting

[metalworker0]

Made the middle sill repair section , put in drainage slots and painted it with zinc weld through paint. too windy to weld it in place
slots must be just above flange as diagram

[metalworker0]

better diagram

[metalworker0]

Details of inner sill showing one of the swage's that lines up with slots in the middle sill, when i make the inner sill repair section I've got to create these

[metalworker0]

Waiting for the wind to stop gusting .
looks like this now; panel in position ..spot weld holes drilled ..and magnets holding the other side.
bit of a gap to fill at one end 3mm ..made it slightly too small ..second attempt ..not making another ..will just bridge it with the weld ..

[metalworker0]

The joint you see in the last post - middle sill..most of it is overlapped ..as there are constrictions of space, with inner sill in the way and large heavy box section stopping torch from getting the right angle for butt welds.
The same will happen on the inner sill .
Another diagram to explain it better.

[metalworker0]

About as good as it gets considering circumstances ..lying on back getting showered with sparks ..hardly any room to work, thin metal . just have to put a bit of seam sealer over it and paint with zinc paint.

next job is to fabricate the inner sill

[metalworker0]

Have to make these forming tools to put the swage in the inner sill