Under sill repair sections

Andries

Andries

Member
Hi Guys,

Main problem ; Inner sill detached from floor, as it is part of the original pressing is should be quite difficult to weld, but not impossible. What I'm not looking forward to is dismantling the complete outer sill including the supports for the B-C Post and D Post and jacking points. I really don't have a choice though, because the outer sill will be rotten behind it and I'm not good at half-assing a job, that won't bring me any peace of mind and will keep on nagging. So with that out of the way that leaves me with a couple of problems.

1. The pins of the lower door hinge are going through the supports and are welded on the outside. What happens if you completely remove the supports? How do you ever get it back in same position and what will happen if you don't get it right?
2. Quality of repair sections of B-C-D post supports? Does anybody have ordered them or used them before?
3. Strength? Is it really nescessary, I'm not going to do a full respray or anything, so I'm a bit reluctant to weld bars between the posts.

Best regards,
Andries
 
If you can tackle both sides of the sill separately (e.g. do the inner then do the out afterwards) you wont need to worry about the structure moving... They're pretty strong!

Rich
 
Hi, I am a little confused when you say the door hinges are welded on. they are bolted.

I am glad you want to do the job properly. If you don't want to weld bracing bars on then
why not bolt them on using hinge, door catch or seat belt anchorage points?

Colin
 
Andries, I looked at my car today and I think I understand what you mean about the hinge supports on the C post. The body part of the hinge bolts onto a plate that is welded onto the C post. In my very limited experience all I can think to suggest is that you mark some reference points on bodywork close to the plates and take some careful measurements. Usually measuring from 3 different points will give good accuracy. After you have replaced the C post metal, you could lightly tackweld the plates in place and trial fit the hinges and rear door. The P6 door hinges have height adjustment and you can also add or remove shims on body and door. So the location of the plates is maybe not very critical.

Again from limited experience, I would maybe try to repair the B C posts in sections to reduce the risk of the car body distorting?

I am a little surprised that you have rust up to (both?) hinges on your car. Most of what I have seen on this forum means rust is usually confined to floor, sills and bottom of A B C D posts?
 
Thank you for your replies. Sorry for being a little vague as I don't have the correct terms for what I exactly meant, but, for illustration I've made a couple of pictures. What I mean is the small piece of metal that holds the door open, there is a rod that goes down, through the sill and is welded on to the undersill section of the B-C post. The problem is, if I remove the under-sill part of the post, how will I ever get this rod back in the same place and thus preventing my door(s) from jamming.

The highest point of rust on the car is about 2 inches high on the sills, as you can see in the pictures. Everything higher than that is 'flying' rust on the inside of the sills and I'm not removing any part of the sill higher than 2,5 inches! At the moment, I'm not going to remove the doors, should give some strength (and I don't care about the bodywork, as it's very bad paintjob and I like burnt grey a lot!)


20130121_112650


20130121_112636


20130121_112700

Kind regards,
Andries
 
Thank you for your replies. Sorry for being a little vague as I don't have the correct terms for what I exactly meant, but, for illustration I've made a couple of pictures. What I mean is the small piece of metal that holds the door open, there is a rod that goes down, through the sill and is welded on to the undersill section of the B-C post. The problem is, if I remove the under-sill part of the post, how will I ever get this rod back in the same place and thus preventing my door(s) from jamming.

The highest point of rust on the car is about 2 inches high on the sills, as you can see in the pictures. Everything higher than that is 'flying' rust on the inside of the sills and I'm not removing any part of the sill higher than 2,5 inches! At the moment, I'm not going to remove the doors, should give some strength (and I don't care about the bodywork, as it's very bad paintjob and I like burnt grey a lot!)


20130121_112650


20130121_112636


20130121_112700

Kind regards,
Andries
 
Andries, you can leave that post in place as it's unlikely to have any serious rust in the inside. When you cut the bottom off the A post or B-C post just leave 10mm all the way round the door stop post and you won't have any worries about alignment.
 
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