53 replies to this topic

[flatline]

I started removing the wax oil from under the drivers side front wheel arch and spotted some dodgy welds.

I'm not sure how its supposed to be but I don't think this it it lol,there is a plate welded on top of another plate which is welded to what looks like the original arch.There is bare metal behind the plate and the welds I popped off with a screwdriver.

I took some pics for your viewing pleasure lol

The red line is one plate and the green is the other.


(Just uploading pics now)

Edited by flatline, 06 March 2013 - 01:43 PM.

[flatline]

Here are the pics.

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[sonikk4]

By the looks of that somebody has welded a replacement flitch panel over the old one.

Not a good thing to do as if the old damage has not been cut out all its going to do is sandwich the rust and rot both panels out.

Have a look inside the car to see whats going on.

[flatline]

Looks fine (to my eyes) from the inside,you can see the outline from the welds on the other side but it looks like one piece.

Ill post the pic when I've resized it.

[flatline]

Here it is from the inside.

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[sonikk4]

I would take those plates off to see what is going on. Its a rust sandwich that needs investigating.

[flatline]

Started cutting away at the cover plates and found a bit of surface rust and was thinking why bother covering that up? Then i cam to the corner and it was rotten,only a very small area but still rusted through.

After cutting it away it looks like there is 3 or 4 pieces of metal that all meet/overlap in the same spot.

Whats the best way to fix this?

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[sonikk4]

Bad news, you have oversills. That will need to be sorted out as they tend to cover up nasties.

As to the flitch i would buy the repair panel and cut out that area that was covered by those plates. There is a lot of surface rust there so remove it in one go.

What is the A panel like, any rust at all?? if so whip that of and you can replace the A post flange that the A panel wraps around.

[flatline]

Looks like i need to buy a welder and read up on these repairs :/

Forgive the stupid questions but which picture can you see the oversills? What order would you do the repairs? What's the best way to revive the oversills?

I've never had to do metal repairs so I don't want to cut to the wrong bit or cut to much off lol

Cheers :)

Oh,did you used to be called something else on the forum?

[sonikk4]

this is the picture showing the oversill. Now if you are very lucky and they have only been on a short time then you may get lucky with the inner sills. Have a look at the Project Paddy link below to see what i mean.

Do not revive them they need to be removed and short sills fitted instead. Again have a look at the Project Paddy link and i have done exactly what you need to do.

[flatline]

Just had a read through the paddy thread,week that's a lot of work to go with money I don't have lol

[sonikk4]

The expensive bit is buying the welder, Panel wise it was cheap. Everything else is for the resto next year so all i have done is replace two sills, one A panel and repairs to the flitch. One hand made and the other shop bought. And jacking points.

Believe me those sills could cause you some serious grief if left. I was lucky as they had removed the old sill but the damn thing was not welded on properly and the inside of the inner sill was not treated at all.

The amount of work looks daunting for somebody who has never done it before but it is straight forward.

For what you need to do is as follows
1:- Remove the oversill

2:- Cut out the remainder of the flitch that needs replacing. If the A panel is crusty then remove that.

3:- Replace the flitch section.

4:- Fit new A panel if required.

5:- Fit new short sill. I would recommend a M Machine short sill.

[flatline]

The bit that worries me the most is removing the bits I need to replace,I'm like Jezza from top gear,if in doubt use a bigger hammer lol

This one any good? I'd rather use one without gas if possible.

http://www.machinema...tails/010112180

Edited by flatline, 06 March 2013 - 09:21 PM.

[sonikk4]

Ahh that's where things go wrong. gasless is for a lot of people not good unless you are skilled at using it. Gas is the way to go especially Argon CO2 mix. This can be bought from Adams gas at a reasonable cost.
And i have always been sonikk4 on here.

[flatline]

Two very good friends of mine are welders,one of them live a few miles away and I was best man at his wedding so no doubt he will get a call lol