13 replies to this topic

[Aridgerunner]

I'm in the process of replacing the inner sill, the outer sill and door step. I have it all mocked up with the door in place. The door alignment at the body creas just below the windows is perfect. The gaps at the edges are very good.

The gap between the bottom of the door and the door step is about 3/8". If raise the door step to reduce the gap it is then too high to line up with the front fender lower edge and the rear quarter panel lower edge.

Is the 3/8" gap typical?

Your help is appreciated.

Bill

[sonikk4]

Bill there is normally a gap somewhat larger than elsewhere around the door. However you can overcome this issue by adding a length of 3.2mm welding filler rod along the bottom. Have a look at the Project Paddy link in my signature to see how it's done.

[Aridgerunner]

That's what I suspected. Thanks for the confirmation. If after everything is welded in place I'm not happy with the gap I will add your trick to the bottom of the door.

Thanks again,

Bill

[DomCr250]

Double check the door size ... Some may have been poorly reskinned and are slightly too short. I had this with a trial fit of a spare door I had lying about, gave me a real shock until I tried another door and found the 1st door was a quarter of an inch too short.

[Aridgerunner]

Good grief! I never thought of that one. This car was poorly repaired by some ham fisted fool years ago. I'll have to climb into the back of the barn and look at the other Mini. And compare left door to right dooron this one.

Bill

[sonikk4]

Is it an original door and skin?? If it's been reskinned and not plug welded/spot welded before folding the skin around then things can move.

[Aridgerunner]

Is it an original door and skin?? If it's been reskinned and not plug welded/spot welded before folding the skin around then things can move.

I'll take some pictures tomorrow and post them.

And before anyone asks; checking the door gap on the 1970 Mini would be pointless because those sills are a mess and I would not trust the measurement. I do however think the 70's doors are original. So the overall height measurement should be correct. I'll know more tomorrow.

Bill

[DomCr250]

Bill you should have a base line for the sill step with what's left of the bottom of the A panel (if anything) and the bottom edge of the rear quarter panel. These two points should be inline, so that gives you a fairly good indication that the door step is in the right place.

If you trial fit the outer sill you can then check it sits on the floor / inner sill about right, that then gives you another set of points to check the door step ... The cars were almost hand built in the factory, so I don't think they were ever that perfect in the first place!

Edited by DomCr250, 04 November 2016 - 07:58 AM.

[Aridgerunner]

I have attached some pictures for your reference and took more measurements.  But let me back up a little.

 

Before I cut out the existing inner sill and door step I welded in some bracing, keeping it parallel to the top edge of the existing inner sill.  I recorded the dimension so I could install the new parts in that exact location.  After temporarily installing the new inner sill on the left side I measured the opening from the lip under the roof to the top edge of the sill.  I then compared that measurement to the right side and found them to be the same.  So I believe I have the inner sill and door step at the correct location.

 

Today I measured the overall height of both doors on the 1978 car.  They measure 37” in the middle.  Then I measured both doors on the 1970 car.  They both measure 36 ¼”.  Go figure.  The doors on the 78 have the door skin welded to the frame and appear to be original.  The picture should confirm that for you guys.

 

I have pop-riveted everything in place and still have that gap so, I guess that gap is supposed to be there.  If I don’t like it when everything is welded in place then I’ll add to the bottom of the door edge.

 

Thanks again for your help.  Back to the garage I go.

 

Bill

 

 

Attached Files

•  DSC_0446.JPG   46.69K   47 downloads
•  DSC_0447.JPG   26.42K   30 downloads
•  DSC_0448.JPG   32.1K   29 downloads

[sonikk4]

I see the problem and it's the magnum doorstep you are going to use. They are notorious for being a very poor fit, poorly pressed and just fit for nothing.

[sonikk4]

The fact you have the bottom of the rear quarter missing is not helping either. I will see if I can rustle up some measurements that may assist you for the quarter panel. I also have measurements for the door cutout as well so I will post those up for you shortly.

[sonikk4]

I cannot post up the picture i want to Bill but as a guide using the swage line on the quarter panel to the lip, the measurement is 21" 

 

Now use this as your guide to get the height of the step correct.

[Aridgerunner]

Here's the update Niel. When I cut out the section of the quarter panel I did it in such a way as to save it. So I clamped it back in place and measured down from the swage line and the lip is at 21" as you noted. Then with just a little adjustment I got the door step to match and tack welded it in place. The shape of the step matches the A and B posts perfectly and the gap is now about 1/4". It looks just fine.

Now all I have to do is weld everything in place. The old spot welder is gonna get a workout.

Thanks for your help. I'll post more pictures later next week.

Bill

[sonikk4]

Happy days. Those magnum door steps are terrible pressings though. I spent ages on two of them for my lads car, salvaged one and binned the other. I then made my own.

I get a local metal fabrication shop to make mine now. A hell of a lot cheaper than Heritage.