17 replies to this topic

[850mini]

Hi again,

I am about to weld in my new sills, as my other thread clarified the questions I had.

However, the flange that the sill spot welds to is rusty. Not all the way along, but there are a few parts that are completely shot. I have stripped back the paint on the doorstep, and the is no filler and no rust on the bottom of the actual doorstep or rear quarter-just the flange.

How would you repair this? Welding on a new flange wouldn't look too good, as the weld would build up. My other idea was to make a 90 degree piece to weld behind the doorstep/rear quarter. Here is a highly technical drawing;



This would mean there would be no weld build up on the outside, and plug welds would be ground down and skimmed after welding the sill on.

What do you think? Would it just trap water and rust?

Thanks

[minimartin1]

I welded the flange on mind. I used a wire brush on the drill to clean it up then welded the hole up and then used a belt sander to get it looking right. Turn the welder down a notch and it was fine

[850mini]

So did you just weld on a strip of steel?

Thanks

[Shifty]

If the flange has gone then the rest won't be far behind it.

[850mini]

The flange is rusted about half way, not completely up to the body. Doorstep is clean metal.

[Shifty]

Only is you're sure. I've pulled plenty of them off and once they start to go its game over.

[sonikk4]

I'm with Shifty here, once the rust starts there will be more lurking. Have a really good look along the inside of the door step. I started doing an insert repair on Project Erms door steps but when i had a good look inside the step there was more rust lurking so i changed the complete step on both sides (along with most of the car in the end.)

Its entirely up to you but bare in mind if you leave any it will eat its way through.

[850mini]

I'll have a really good look tomorrow, but so far the flap disc has uncovered nothing but nice shiny metal. The last thing I want is rust though, I'll have a really thorough look around.

Provided the doorstep is rust free, which method of flange repair would you go for?

Thanks

[Shifty]

On the top, looks ok?



Once chopped out..



Need I say more??

[850mini]

But didn't that have a panel spot welded over it covering up the rust in the first pic?

[Shifty]

Yup, the rest was shot and pitted too. That pic show what happens if you spot weld a panel over ir.

Its just not worth messing with, replace the panel and have done with it.

[850mini]

Hmm, that might be the best option. I Just think it's shame because it's all original and solid. The flange is just rusty all the way along, maybe 5-7mm from the edge.

Edited by 850mini, 24 December 2011 - 09:39 PM.

[BusheyTrader]

Hi,

My driver's side doorstep panel was shot to bits with rust so I had to replace the whole panel.

I view the sills as a wet / damp area so I'd be worried about having a lap joint facing upwards when moisture will always try to trickle down it. I prefer butt welding since it's waterproof.

I'd cut / grind off the 90 degree flange from the doorstep and weld a replacement strip on from behind. Or if you can form a long thin "L" shape, cut further up and butt weld again from behind for minimal grinding on the outside. The 90 degree angle should keep some of the distortion in check. Difficulty factor of 9 3/4 out of 10 especially for me though.

Or read a more sensible solution from the more experienced.............

Adam

Just read the posts placed while I was typing, my doorstep panel had 5 bubbles of rust topside but was infested with it as per Shifty's photo, and the pattern panel I used needed lots of fettling.

Edited by BusheyTrader, 24 December 2011 - 09:45 PM.

[Shifty]

And when the new panel was fitted..

[sonikk4]

If you are happy there is no rust lurking then i would go for just adding another lip then tack this in place the full length of the repair. Then pulse weld along the repair section and grind back.