DIY Sills - what size box?

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I’m hoping to swap it out for the galvanised one I have just bought. I don’t have the space at the minute, but a farmer friend has an old barn I can use, it’s a question of when I can get it cleared enough to do the job.
If you can do that in a weekend I'll be super impressed. :)
 
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Nice "Safe" working practices going on there! o_O

This particularly I’d giviNg me palpitations and anxiety.... there is literally NO a reason to do this on your drive imo

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If you can do that in a weekend I'll be super impressed. :)
I managed to do the same thing with the bulkhead on my series 3 in two days on my own. It was over an Easter bank holiday but I started Thursday evening and finished Saturday afternoon. I know there is more on a defender one but is should be doable and if you can secure a willing volunteer for two days is should be easy.
 
I managed to do the same thing with the bulkhead on my series 3 in two days on my own. It was over an Easter bank holiday but I started Thursday evening and finished Saturday afternoon. I know there is more on a defender one but is should be doable and if you can secure a willing volunteer for two days is should be easy.
I'm super impressed :D
 
This particularly I’d giviNg me palpitations and anxiety.... there is literally NO a reason to do this on your drive imo

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That is just ridiculous.

I have always wondered what the need for jackable rock/treesliders is. Surely even in an off road recovery situation you could use a hi-lift mate that hooks to the wheels if you needed to lift the side?
The only advantage I could see is if you needed somewhere to winch sideways from, but that would be a different loading to jacking.
 
I managed to do the same thing with the bulkhead on my series 3 in two days on my own. It was over an Easter bank holiday but I started Thursday evening and finished Saturday afternoon. I know there is more on a defender one but is should be doable and if you can secure a willing volunteer for two days is should be easy.

I did an almost identical thing on my 90 over an Easter holiday with a lazy start on the Friday - I fitted a new bulkhead - my volunteers tapered off by about Saturday lunchtime - but I was back on the road again by the Monday and that included stopping for much of Sunday for a family Easter meal, chocolate eggs and ale, although I think a lot of family were taken on trips out to the garage to see the progress which resulted in, "Oh could you just give me a hand on with this wing while we are here!" The garage had never seen so many helpers dressed in their Sunday best!
 
Well, your both faster workers than me. :oops: Even now, having done it once and know what's involved, I doubt I could do it in a weekend. I reckon mine would still come apart easily too! :(
 
Well, your both faster workers than me. :oops: Even now, having done it once and know what's involved, I doubt I could do it in a weekend. I reckon mine would still come apart easily too! :(

If I am honest with you, it took me weeks of planning to enable me to do this, I had boxes and boxes and boxes of parts, seals, wire, connectors, grommets, fasteners, adhesives, sealants, tapes, pipes... I literally worked it out step by step and laid everything out around the garage so that I could just keep pushing on.
 
If I am honest with you, it took me weeks of planning to enable me to do this, I had boxes and boxes and boxes of parts, seals, wire, connectors, grommets, fasteners, adhesives, sealants, tapes, pipes... I literally worked it out step by step and laid everything out around the garage so that I could just keep pushing on.
Same thing for me, I had all of the parts that needed replacement or may have needed replacement. I had carefully planned all of the steps for it and spend the two weeks prior soaking everything with penetrating fluid.
The only problem I ran into was the end of the sills had disintegrated so needed some welding and new end plates making up (far easier than the OP's station wagon sills). Other than that is all went smoothly.
I also had an enormous warehouse to work in which made things a lot easier. This is just tucked in the corner of it:

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I’m hoping I don’t run into too much rust and repair work. On that note though, would you consider repairing any chassis steel with TIG? The reason I ask is we have a large 3phase MIG machine at work that I have used for the last few years and have it really dialled in, but at home I have a 180A AC/DC TIG, 170A stick, or a hobby MIG. The MIG machine isn’t that great, but the TIG worked alright last time I fired it up. I don’t fancy welding it with stick, as I don’t think I have any rods less than 3.2mm. What would you use? Work is 15miles from home, so would need to be trailered to work for any repair work.
 
60x60x3 box section cut to length and offered up , then made brackets and welded on with bolt holes to match up with existing.
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I put tread plate back on as I had it lying around
 
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