Finished the OS rear sill today and achieved my ultimate goal - being able to support the car off the sill jacking points.
It's a great feeling when you add strength back into a cars structure. I know it's pretty strong as my rapid lift jack dropped the car onto the stands in a very ungracious way. These rapid lift jacks do tend to do that I've found. I had made some blocks to fit around the jacking points so there wasn't too much danger.
I'm afraid I didn't take any photos of the metal fabrication as I was in the zone, but nothings hidden. When I did the Lagonda I had to fabricate so much that I did quite a bit of research into finding an 'easy to use' metal cutter - and I found one - the Bosch shown below. It's really really fantastic and saves so much time and effort, it produces lovely safe edges too - well worth the money. Making the sill drain holes took a bit of practice, the metal is 1.2mm so not that easy to shape. I used a chisel to cut the slots, then a big socket and hammer to create the right shaped outlet - photo to follow...
I've only primed and underguarded the repaired areas - I'd love to match the original underseal but not sure if that's possible. One slight mistake is the position of the little round X plug - a bit too high...but I'm sure I measured its position correctly! Not a big deal as this was formally plated over with rubblishy metal - so nice to see it again.
I injected all of the cavities and sills etc with Dinitrol 3125 HS cavity wax - I do hope I don't have to weld in this area again
- Sill-repair.jpg (57.23 KiB) Viewed 14184 times
- Sill-Repair1.jpg (68.41 KiB) Viewed 14184 times
- bosch-gsc12v-13-metal-shear-ptuk-1017.jpg (25.09 KiB) Viewed 14184 times