HELP..! Mk1 Fiesta Inner + Outer Sill

[jonowilliams]

Hi, I am needing some advice on how to weld a new inner sill on my Mk1 Fiesta... ie how were to cut the old one off and getting the new one on... its a full inner sill replacement and outer.. any help would really be appreciated.. thanks in advance

Jono

 

[malcolm]

http://www.mig-welding.co.uk/sills.htm for the basics on sills.

Main things for me are to keep the body straight and for restoration work join to the original flanges. There's a bit about unpicking old spot welds when you won't want to keep one of the panels here: http://www.mig-welding.co.uk/removing-floor.htm

 

[jonowilliams]

http://www.mig-welding.co.uk/sills.htm for the basics on sills.

Main things for me are to keep the body straight and for restoration work join to the original flanges. There's a bit about unpicking old spot welds when you won't want to keep one of the panels here: http://www.mig-welding.co.uk/removing-floor.htm

Cheers bud

 

[Chickenjohn]

Are you restoring the car or just welding it up to get through a few MOT's??

What is needed fro proper restoration and for MOT pass are two different things.

A classic Aston deserved the full resto treatment a la Malcolm, but this may be overkill if you are just aiming to get the Fiesta back on the road!!

 

[malcolm]

You should see the standard I reserve for Renault 4s - way higher than any Aston stuff.

But true enough - the top of the inner sill don't look bad. It's removing the the inner sill while leaving everything else intact that takes the time. Another option could be removing the rusty metal from the inner sill, use only the bottom half of the replacement inner sill and weld that to the sound part, then fit the new outer sill as normal. Would be fine structurally and save a lot of work.

 

[jonowilliams]

Are you restoring the car or just welding it up to get through a few MOT's??

What is needed fro proper restoration and for MOT pass are two different things.

A classic Aston deserved the full resto treatment a la Malcolm, but this may be overkill if you are just aiming to get the Fiesta back on the road!!

its a restoration bud.... the owld girls been stood outside for 15yrs+ and ive just noticed both sills need doing and it needs to be strong as its not going to be original... its getting the subaru impreza wrx upgrade ..

 

[jonowilliams]

You should see the standard I reserve for Renault 4s - way higher than any Aston stuff.

But true enough - the top of the inner sill don't look bad. It's removing the the inner sill while leaving everything else intact that takes the time. Another option could be removing the rusty metal from the inner sill, use only the bottom half of the replacement inner sill and weld that to the sound part, then fit the new outer sill as normal. Would be fine structurally and save a lot of work.

threw the great big dirty hole in the outer sill i can see the back of the inner sill and its just rust.. looks asif its being held together by the paint

 

[Chickenjohn]

If it's that bad, then you need to weld a brace between the door pillars to keep the car the same shape! Weld brace so you can still shut the door, measure everything, then you can cut the rusty sill off.

 

[jonowilliams]

If it's that bad, then you need to weld a brace between the door pillars to keep the car the same shape! Weld brace so you can still shut the door, measure everything, then you can cut the rusty sill off.

aye i knew as much as that mate... just my first time and im clueless...!!

 

[Chickenjohn]

You'd be surprised how many people do just wade in with no thought as to how to keep the car in the same shape!

 

[white van man 2]

i had a mate who put a sill on an x1-9. when he bolted the door back on after, the doorframe was out by nearly 2 inches

 

[Chickenjohn]

Exactly! Not bracing the car before cutting can be even more of a problem when the car is a convertible!

Had he measured everything anc checked his measurements after tacking the sill in place he could have undone the damage.