Bodywork woes

Discussion in 'Mech Tech' started by DubCat, Nov 25, 2018.

  1. remember PREVENTION IS CHEAPER THAN CURE ie welding
     
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  2. shielsy likes this.
  3. DubCat

    DubCat Sponsor

    Sure is. I won't be competing with that.
     
    shielsy likes this.
  4. DubCat

    DubCat Sponsor

    OK so here is what's left of the sill:
    [​IMG]
    Bottom edge cleaned up:
    [​IMG]
    And the top one:
    [​IMG]
    This is the sill roughly clamped in place. I've bent the top edge of the sill to a right angle so I can get to the underside of the lip to do a load of plug welds - haven't drilled the holes yet. Once they're all done, the plan is to bend it back round and clamp the bottom edge to weld.
    [​IMG]
    However before I weld this plate in:
    [​IMG]
    There's a bit of a problem behind it that I'm not sure what to do to fix it:
    [​IMG]
    There's a hole at the bottom that I've cleaned up a bit and one to the left just inside the cavity. Not sure if I can get in there to weld it. Any suggestions please folks?
     
  5. drill a hole with hole cutter paint it both side s leave over night , then weld it in , the hole now is an access point to blow stone chip and some zinc primer mixed inside then close with a rubber bung , that inner sill is in some condition lovely job :thumbsup::thumbsup::thumbsup::thumbsup::thumbsup::thumbsup::thumbsup:
     
    Last edited: Dec 9, 2018
    DubCat likes this.
  6. did i say that YELLOW IS MY favorite colour
     
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  7. mikedjames

    mikedjames Supporter

    You do know sills are three layer ? Inner, outer and middle.

    Theres a heavy stiffening piece in the middle which gets deleted by bodgers.
     
    p.tinks likes this.
  8. DubCat

    DubCat Sponsor

    Am I missing that Mike?
     
  9. I believe vw omitted the middle layer on the non sliding door side for later models. That’s what Fletcher Gillett says anyway.
     
    DubCat likes this.
  10. DubCat

    DubCat Sponsor

    Phew. Mine is a 76. Certainly doesn't look like anything else missing now I've removed the outer sill.
     
  11. 77 Westy

    77 Westy Supporter

    My ’77 German spec bus had/has an inner, middle and outer both sides. It doesn’t have and never has had belly pans though.
     
    Last edited: Dec 11, 2018
  12. DubCat

    DubCat Sponsor

    Mine is a South African import - would they be different? There really is no evidence that there was ever anything goes else in there that I can see.
     
  13. Mines a South African import too. Loads of stuff missing. Built out of what was closest to them, not necessarily what was in stock.
     
    DubCat likes this.
  14. Mine’s a German spec bus, 79 and has no middle layer either on the sills or the front end of the rear arch on the left hand side, but all three on the other side. I’m assuming it’s bracing for the open dooway not needed where there’s a solid panel.
     
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  15. The middle sill was deleted on later model late bays on the non sliding door side. Not sure when they started. I omitted it when I redid my 73.
     
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  16. DubCat

    DubCat Sponsor

    Finally got some time on the bus.

    So first I painted inside the sill channel, hopefully prolonging the life of my chassis a bit.

    [​IMG]

    Next welded a plate over the hole above the jacking point and welded the cap on the end at the front wheel arch end.

    [​IMG]
    [​IMG]

    I figured my plan to bend the sill in place once the top edge has been welded might be a bit flawed. The top lip of the new sill is stronger metal than the lower lip of the old body panel, so if I tried to bend the sill inwards, it would just deform the panel. After some head scratching I dug out some old brackets I'd had for ages and started chopping then up to make some braces.

    [​IMG]

    Shaped them a bit to fit - you get the idea:

    [​IMG]

    I welded a few in place and the lower panel lip is much more solid.

    [​IMG]

    A few plug welds in the upper lip of the sill from the inside - like this (OK so I only photographed the best ones close-up)

    [​IMG]

    And 24 plug welds later:

    [​IMG]

    Painted inside again

    [​IMG]

    I'll let that dry and next time will attempt the bend and weld the bottom edge. I did a bit of a test and I think I'm going to need to use a lever to brace the edge still as the panel still moves a tad, then heat the top edge of the sill a bit to help it bend.

    I'll get back to you with the results in due course.
     
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  17. Is bending it tbe right approach? Can it not be tacked in and the plugged top down?
     
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  18. DubCat

    DubCat Sponsor

    Not sure what you mean. Can you explain please? If there's a better way, I'd be very happy.
     
  19. Firstly I’ve not done a sill in a bay... but I’ve done lots and lots of mini panels. I’ve never had one I’ve needed to bend in. I can’t imagine it working well.. so I think I’d be looking at if I could weld it down from the lip above. But I’m not sure what’s in the way?
     
  20. DubCat

    DubCat Sponsor

    The problem is that to weld the top lip from above, you'd have to cut out a section of the cab floor, which is obviously out of the question. Another method is to use a larger sill panel and cut in further up the upper body panel, again I didn't want to do this. I think my method works, as long as I can bend it neatly. I'm determined to solve this - I'll let you know if it works!
     

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