25 replies to this topic

[kenyon]

So parking the sill issue for now, when it comes to the floor pan which I have just received from Mini Spares.

 

Should I overlap for welding, if so by how much?

Is spot welding acceptable or should it be more of a seam weld?

Should I weld on the inside or the outside of the shell?

 

Thanks all

[sonscar]

Legally it should be seam welded and ideally butt welded for best corrosion resistance.Weld from whichever side is easiest.Have fun,Steve..

[kenyon]

So I decided after all the top advice to take the 'long' sills off, oh boy am I happy I did, look at the state of this, its not the worst I have ever seen but certainly more than I expected when the previous owner said 'the underneath is all done' !!!

Check out these:

https://youtu.be/drbK3uLf8eQ

https://youtu.be/OxII-r7LLSc

https://youtu.be/Lqn0ddayMS0

 

 

And a couple of photos for good measure.

 

Any suggestions on how to repair the inner sill bits?  Without replacing the whole lot?

Attached Files

•  20220402_114647.jpg   90.05K   0 downloads
•  20220402_114642.jpg   86.88K   2 downloads
•  20220402_114639.jpg   95.67K   0 downloads

Edited by kenyon, 02 April 2022 - 04:19 PM.

[nicklouse]

If you need someone to have a look at it just shout. I am local.

 

just looked at the first video. The clutch set up and brake servo set up are from incorrect years. One is wrong. And the fan is on the wrong way round.

[kenyon]

If you need someone to have a look at it just shout. I am local.

 

just looked at the first video. The clutch set up and brake servo set up are from incorrect years. One is wrong. And the fan is on the wrong way round.

Sorry have you replied to the wrong thread?

[sonscar]

Seriously look at m-machine? Panels,they do a nice inner sill and floor to first flute repair.I have used it myself and it is excellent and replaces all of the crud you can see.Combined with their outer sill it makes a good repair far easier than repairing what you have.Steve..

[nicklouse]

 

If you need someone to have a look at it just shout. I am local.

 

just looked at the first video. The clutch set up and brake servo set up are from incorrect years. One is wrong. And the fan is on the wrong way round.

Sorry have you replied to the wrong thread?

 

Nope.

[Homersimpson]

You have a few options, the best way as mentioned above is the M-Machine inner sill to first flute of the floor, this will solve all of your problems and give you a great base to build off.

 

If your not as confident at welding you could just cut our the rot and weld in patches, either on the inside where you can get to them, on the outside or butt weld them in and grind back. if your feel adventurous.

 

The video you have of the over sill being removed is typical of their use and is one of the main reasons why people don't like them as they hide a lot of sins as you have found.

 

For grinding back fibre disc are great (the blue zirconia ones rather than the red ones) and I also have a Black and Decker electric finger belt sander (KA900E) which again I use the blue zirconia belts (bought from e-bay) and this helps get into all the really awkward places and is great for a final clean up of the steel before starting to weld.

Edited by Homersimpson, 02 April 2022 - 10:31 PM.

[kenyon]

Seriously look at m-machine? Panels,they do a nice inner sill and floor to first flute repair.I have used it myself and it is excellent and replaces all of the crud you can see.Combined with their outer sill it makes a good repair far easier than repairing what you have.Steve..

 

 

You have a few options, the best way as mentioned above is the M-Machine inner sill to first flute of the floor, this will solve all of your problems and give you a great base to build off.

 

If your not as confident at welding you could just cut our the rot and weld in patches, either on the inside where you can get to them, on the outside or butt weld them in and grind back. if your feel adventurous.

 

The video you have of the over sill being removed is typical of their use and is one of the main reasons why people don't like them as they hide a lot of sins as you have found.

 

For grinding back fibre disc are great (the blue zirconia ones rather than the red ones) and I also have a Black and Decker electric finger belt sander (KA900E) which again I use the blue zirconia belts (bought from e-bay) and this helps get into all the really awkward places and is great for a final clean up of the steel before starting to weld.

Thanks for the advice, if I remove the inner sill as well do I need to temporarily put a brace bar in to stop deformity?  I had a look on M-Machine I think I found the bits you refer to:

11.31.04.27 Inner Sill, LH, Mk1-5 £28.50 £34.20

11.31.04.28 Inner Sill, RH, Mk1-5 £28.50 £34.20

Would these be the right ones?

Or do you mean the inner and outer complete set?

Thanks

[Homersimpson]

You would probably need to breace the door apature to stop any movement.

 

I had a look in the M Machine catalouge but couldn't find the numbers above, if you give them a call and tell them what you want and what year the car is i'm sure they will be able to help advise what you need.

[kenyon]

I know its been over a year since I posted anything, to be honest not a lot happened in the past 12 months I am now however back on it and I want to make some serious progress this year.

 

I have finished the passenger side sills/ floor and lower bulkhead and I have moved over to the drivers side.

This is much worse, rot up the A-pillar up to the first door hinge hole and across some of the main floor cross member.

I have cur out a lot more metal, see attached and have taken the decision to remove the step and door A pillar to bottom of windscreen.

I have peeled away the layers of patches at the top of the inner wing to reveal a load more rot up there.

I have had to cut away the badly installed scuttle panel end piece to get access.

 

I have a couple of questions:

 

How do I ensure the A pillar and step are installed so the angels are correct for door fitment and in line with a non existent front wing?

 

Should I keep the 'vent' hole that is in the new inner wing panel or just fill it and not bother with it, what are advantages and disadvantages?

 

Thanks all and I hope to post again very soon.

Attached Files

•  20240210_150822.jpg   63.01K   4 downloads
•  20240210_142511.jpg   63.67K   4 downloads

Edited by kenyon, 12 February 2024 - 03:01 PM.