Chaps
I am trying to finish sticking my 1984 BMW 635 CSI back together, bloke I hired has done all the inside stuff and stuck the new sills on, sadly he didn't do it the way I would have, and left the old sills underneath. I am now trying to plug weld it all together but am having problems.
The inside edge of the floorpan has been rebuilt with 1.5mm angle, there are also sections of 1mm sheet sticking down from the inside where the inner sills have been reinforced. The remains of the old sills are inbetween this lot and the new outer sill section. I have given it a good clamping together and stuck a plug weld in, but as there is a double layer of steel on the inside, then a 0.8mm old sill edge, then the 0.8mm outer sill. If I get the power high enough to penetrate the inner pieces, the outside stuff melts off, if I keep it low enough to not melt the outer bits, there's no penetration.
Anyone have any tips? I am thinking of some strip clamped to the outer aspect, drill right through then fold the bottom edge over so I have thicker stuff inside and out to help keep things together. I will do a bodge weld in the meantime as the car has to be jacked up and moved as the space it is in has been rented to someone else - I now have access to a 2 post lift which compensates for having to move the car.
Cheers
Jim
I am trying to finish sticking my 1984 BMW 635 CSI back together, bloke I hired has done all the inside stuff and stuck the new sills on, sadly he didn't do it the way I would have, and left the old sills underneath. I am now trying to plug weld it all together but am having problems.
The inside edge of the floorpan has been rebuilt with 1.5mm angle, there are also sections of 1mm sheet sticking down from the inside where the inner sills have been reinforced. The remains of the old sills are inbetween this lot and the new outer sill section. I have given it a good clamping together and stuck a plug weld in, but as there is a double layer of steel on the inside, then a 0.8mm old sill edge, then the 0.8mm outer sill. If I get the power high enough to penetrate the inner pieces, the outside stuff melts off, if I keep it low enough to not melt the outer bits, there's no penetration.
Anyone have any tips? I am thinking of some strip clamped to the outer aspect, drill right through then fold the bottom edge over so I have thicker stuff inside and out to help keep things together. I will do a bodge weld in the meantime as the car has to be jacked up and moved as the space it is in has been rented to someone else - I now have access to a 2 post lift which compensates for having to move the car.
Cheers
Jim