Lovel
Member
Hi there,
There has been a tiny bit of corrosion at the bottom on my drivers side D-post which I have put up with for a number of years. Upon digging deeper I found that it was indeed well past its best with a number of botches over the years. Unfortunately when the previous owner of my car replaced the sills they didn't get down to the bottom and remove all rust. Hence now I am having to remove some perfectly good rust free material to get to it and do the job properly. The photos attached are taken from the rear OS jacking point looking forward.
I am going to replace the complete inner box section sill with new as the existing square holes for the sill covers are too large for the plastic retainers and it seems to be fitted at an angle. As I don't have an original reference point to work from could anyone advise if the inner box sill section comes off the floor pan at a slightly upwards angle or should it be horizontal?. The angle does not show up too well in the photos unfortunately. As you can also see the replacement box section inner sill has been roughly fitted with no attempt to cut the sill into shape, this has the effect of to bending the sill inwards. Any thoughts? Fitting Wadhams panels, full D-post and inner box sill.
Marked up the photo to show horizontal line and angle of sill.
Note the replacement sill fitted but not cut, just bent inwards and slipped up behind original cut sill.
Working my way towards the front bit by bit, but still got a lot of grinding and cutting out to do.
Cutting out relatively new metal is a pain. At least rust is easier to handle. Using a belt sander to grind down the existing welds which is excellent to use but still time consuming.
There has been a tiny bit of corrosion at the bottom on my drivers side D-post which I have put up with for a number of years. Upon digging deeper I found that it was indeed well past its best with a number of botches over the years. Unfortunately when the previous owner of my car replaced the sills they didn't get down to the bottom and remove all rust. Hence now I am having to remove some perfectly good rust free material to get to it and do the job properly. The photos attached are taken from the rear OS jacking point looking forward.
I am going to replace the complete inner box section sill with new as the existing square holes for the sill covers are too large for the plastic retainers and it seems to be fitted at an angle. As I don't have an original reference point to work from could anyone advise if the inner box sill section comes off the floor pan at a slightly upwards angle or should it be horizontal?. The angle does not show up too well in the photos unfortunately. As you can also see the replacement box section inner sill has been roughly fitted with no attempt to cut the sill into shape, this has the effect of to bending the sill inwards. Any thoughts? Fitting Wadhams panels, full D-post and inner box sill.
Marked up the photo to show horizontal line and angle of sill.
Note the replacement sill fitted but not cut, just bent inwards and slipped up behind original cut sill.
Working my way towards the front bit by bit, but still got a lot of grinding and cutting out to do.
Cutting out relatively new metal is a pain. At least rust is easier to handle. Using a belt sander to grind down the existing welds which is excellent to use but still time consuming.
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