18 replies to this topic

[biker1981]

Ok.

So ive got the new sill... how do I get the old one off... do i just cut it before the flat lip at the top.... or should i try and sepaertate the seam at the top?

Also when welding the sill to the lip... do i seem weld it or should I drill holes and puddle weld it??

whats peoples view on painting the inside of the outsill prior to welding ?

[sonikk4]

You can cut the sill off just under the sill/ door step lip then you can either grind back or drill out the spot welds. My preferred method is to drill out the spot welds then reuse the holes to plug weld.

Then for the bottom of the sill drill 1/4" holes roughly one inch apart then plug weld these as well. At the end by the heel board either plug weld or seam weld. The front end plug weld.

Yes paint inside the sill before welding on but leave the flanges where you are welding devoid of paint but use a zinc rich weldable primer instead.

[biker1981]

You can cut the sill off just under the sill/ door step lip then you can either grind back or drill out the spot welds. My preferred method is to drill out the spot welds then reuse the holes to plug weld.

Then for the bottom of the sill drill 1/4" holes roughly one inch apart then plug weld these as well. At the end by the heel board either plug weld or seam weld. The front end plug weld.

Yes paint inside the sill before welding on but leave the flanges where you are welding devoid of paint but use a zinc rich weldable primer instead.

Great stuff..thanks. I was going to drill the welds out... but i just cant see them... not sure if its just me... but just cant see .

[sonikk4]

Is it the original sill fitted or a replacement?? if its been replaced before its more than likely there will be no spot welds as such so you will need to cut the old sill off, grind back the remainder of the old sill lip to the door step lip. Then you can either drill new holes in the door step lip and rear quarter panel lip or drill them in the sill lip and weld up. I prefer to weld down and then sort the paintwork out later that will be damaged slightly by plug welding.