Seperating outer sill from inner and floor pan

[daniboy1_2_3]

Hi there, im in need of some help if anyone can. Im having to replace the outer sill on a VW corrado and as new panels are not an option to me as they didnt manufacture a full sill repair section im having to use second hand panels. I have already managed to ruin one sill attempting to seperate it from the inner sill and floor pan. I know its spot welded but due to the shape i cant get a drill onto the lower lip to remove the spot welds. I tryred slowly grinding away at the other layers but this proved massively time consuming and resulted in me being left with a weak (and burnt through in some places) lower lip.
Im not sure if i have described things enough here but does anyone think they can help at all? cheers.

 

[the snooper]

chisel through the panels not needed and then clean up the remaining spot welds on the panel you do need and on the car it would be the reverse chisel though the old sill leaving the inner intact

 

[daniboy1_2_3]

Are you saying just work from the inside of the sill until im at the edge i want? I cant really chisel much without deforming the straight edge, maybe im not understanding what you mean properly?

 

[gordon stephenson]

Sometimes using an air chisel for this sort of thing works well because of the rapid low impact blows delivered compared to a manual hammer causes much less distortion.

 

[stormin]

I think the problem with trying to chisel it off is the inner sill is a much thicker structural piece. The outer shaped panel you want to preserve is thinner gauge more cosmetic and more prone to tearing with the chisel.

The only way I would say is to drill out most of the spot welds all the way through if necessary. Live with any small holes in the outer panel and plug weld when attaching to the restoration car.

The problem I forsee is finding a really good panel worth re-using. I know all VAG vars were supposedly glavanised but Corrado's are getting to an age were all second hand panels must be starting to corrode.

I must say I'm surprised the outer sill is not the same or very similar to a model of Golf as the floor pan and drivetrain is supposedly basically the same.

 

[daniboy1_2_3]

Thanks for the replies. Yes that is basically my problem, removing the delicate, thinner gauge material from a very strong inner sill section and floor pan. I have ruined one by grinding so i most definately need a new approach. I take it the best way of seeing all the spot welds is to clean the metal right back until it shines? Unfortunately on the reverse side, drilling from inside out the spot welds are pretty much hidden by the other two panels. Im finding it pretty frustrating and i think i ran out of patience with the last one and ended up ruining it. I just need a fresh approach. Maybe a combination of removing as much of the other panels with grinding, chiseling and drilling might be the way.

 

[malcolm]

It's a pain that sort of thing. Spot weld drill where you can, and after that it's best to cut through the other panels to release the sill and then grind the remains of the other panels off afterwards. (assuming you don't want to keep the car the sill is attached to) Getting the panel off the doner car first makes it easier to deal with and prepare.

Was that anywhere near the gist of the problem?

 

[Uniqueusername]

Fibre disk with arbour in a drill will clean up the lip so you can see the welds.
Drill out welds as best you can.
Use a decent sized / decent quality WOOD chisel. (not a cheapo)
You can buy splitting chisels for metal, basically a very thin chisel and they work well if kept SHARP but not as good as the wood chisel.