7 replies to this topic

[Daveymac]

Is there an easier method to removing sills, or more specifically the remaining metal spot welded to the side step? I have removed 90% of the sill and have a small strip to remove from the side step/lip, but so far seem to be bending the lip all out of shape while chiseling the old metal off. I have drilled the spot welds but not all the way through and probably not deep enough from my thoughts, any help or good practice ideas?

[sonscar]

Grind it thinner,when it turns from blue to red it is thin enough to prise off.Protect things from sparks.Steve..

[stuart bowes]

power file / finger sander was my weapon of choice, I found it easier to be accurate and get just through the waste metal without going into the stuff I'm keeping

 

takes ages though if you're being precise

Edited by stuart bowes, 27 June 2025 - 10:29 AM.

[Steam]

Get a spot weld drill bit, works a treat.

[Ethel]

I did wonder if you meant after drilling with a spot drill.  I'd see the remaining spot has an opportunity to make an alignment aid, if you didn't drill on the "keeper" side. As far as chewing off rusty remnants goes, I've found using a set of pliers or mole-grips like a sardine tin key  along the panel join is quite effective.

[68+86auto]

10mm belt sander and roloc sander.

Using the belt sander totally replaces spot weld drill bits. I don't use the drill bits unless I need to save both panels.

[sonikk4]

Personally i use 1/4" cobalt drill bits and a very thin splitting blade, BUT if its just a sill then for speed i cut the majority away with a 1mm slitting disc then play hunt the spot weld with a grinder as invariably if things are very crusty trying to find a spot weld can be problamatic even more so if the sill have been previously replaced.

 

However i have spot weld drill bits with varying success but ill stick to my own mehtod of using 1/4'' drill bit and splitting blade.

 

BUT this also depends on the equipment and facilities you have to hand. Something to bear in mid for novice mini owners.

[stuart bowes]

I did wonder if you meant after drilling with a spot drill.  I'd see the remaining spot has an opportunity to make an alignment aid, if you didn't drill on the "keeper" side. As far as chewing off rusty remnants goes, I've found using a set of pliers or mole-grips like a sardine tin key  along the panel join is quite effective.

Same here sometimes, it's like removing wallpaper, sometimes you get a good bit that goes a long way and just peels nicely. Other times (often) you're picking at tiny bits and that's when the power file came out