7 replies to this topic

[Tinkerbelle]

Hello All,

It is a long time since I did sills but I was wondering if people remove the remaining sill metal attached to the bottom door step when cutting the old sill off at the first bend under the door step?

When you attach the new one this would make three thichnesses of steel which may look poor, but saves a lot of delicate grinding works:).

Also I like to seam weld them, I always seam weld the ends of the door step and outer sill, but this is not very neat looking even after grinding back. Does anyone else have any other methods. I could spot weld but this I consider too weak unless continuous as they roll weld them in the factory (thanks BMH for the tour).

Thanks for any comments

Matt

[Se7enS1ns]

Generally, no, unless severly rotten. The lip on the door step should meet up to the lip on the sill, giving you something to clamp to and spot weld to.

[myredmini]

I always cut the sill off and clean the lip underneath so I have just the door step lip. Zinc prime it to prevent rust. Then fit the new sill by plug welding it with a mig.

Dan

[Se7enS1ns]

^ Ditto

[Tinkerbelle]

Many thanks for that. I thought that might be the best way to go. So I need to practice my plug welds now then, or would 'good quality' continous spots be as good? (I just like my spot welder).

Matt

[sonikk4]

If you spot weld at roughly 1" spacing that will be fine as that is pretty much how it left the factory. The three layers of metal may hinder the spot welder though so would either add more power or just remove the old sill lip.

Plug welds will be fine as well again using the same spacing. That's what i use on both Project Erm and Project Paddy.

[PaulColeman]

I am doing this very job at the moment and I too thought about leaving the lip on as I was too lazy to grind it off (Homer Simpson) but I've decided to grind it off to try and get a better plug weld to hold the new outer sill on. It seems like a lot of effort but I think it's worth doing it as it will be a cold day in hell before I do it again

Paul.

[Ethel]

If you can find the spot welds drill them to remove the sill. If you can't, cut through the sill immediately under the lip, then you can roll up the remainder like opening a tin of corned beef.