The box section I ordered from my local stockists arrived last week, but I ordered the wrong size (100x60mm) , and as they cut the length into 4 pieces so as I could get them in the car, I couldn't take it back !!!!!
Being too embarrassed to re order 120mm from them, I got them from flea bay !!!...

So I'll be putting the 100x60x3.6mm lengths up for sale.

Anyways,
Still wet and showery today, so I started welding end pieces on them in the garage.



One done , one to go.
 
It is.

But 120mm is to the bottom of the lip, and if you also cut away the back bit of the sill and replace body mounts, they are 120mm or so high, so would have to chop 20mm off them if using 100mm.

Not sure if I've explained that properly........
 
Nice and sunny today so I chopped a bit more off the sill.

The rusty looking bit is a piece of angle iron I put under to hold things in place....just in case !!!




Got rear mount off.......fekkin stoopid design !!!!!

 
I had cut away the same nount and my mount was very seized had use alot of wd40 and knock up and down to get it moving. I refitted the mount to the bracket and tacked in place once spot on. Then temove and weld in place then fit and weld all in
 
Aching all over !!!!

Been lying down all afternoon under the Disco scraping a load of black kak off the n/s chassis rail ready for giving first coat of Bonda primer.

Also gave me a chance to see how I'm going to tackle all the holes :(

No photos today.

A few questions later when I get home.
 
Can't remember wot I was going to ask !!

Anyways,

Bit more scraping underneath....

The bit of angle that holds the brake pipe on front to back,was bothering me...
 
So I gave it a bash and poke and decided there was rust hiding there somewhere.....

So I drilled the spot welds to get it off and found this ....



So more cutting out required :(
 
aren't I ......... and I'm slow too !!! lol

.......and I got a knackered back !!!!

hoping to finish cutting out front of sill on Monday and offering up the box section to have a looksee as to how it and the new body mounts fit..
 
Been a while......

Holidays, crap weather , blah blah.....

So today I finished chopping sills out at front , went to se how box section would look and fit ............. And it's to fekkin wide!!!!



Can someone explain to me how 60mm fits into 50mm gap ??

Well ****ed off . !!!!!
 
Chrisw8 said:
Can someone explain to me how 60mm fits into 50mm gap ??
Click to expand...

BIG HAMMER? :p

but seriously, can you trim the outer lip that you have left & just but the box section to what was the inner sill?
ps. I'm glad I've read this as I have sills to do on one of my 200 D1's so now armed with ideas good & bad o_O

Rich.
 
Mad hat man......fekked if I can see 60mm fitting into 50mm unless do as Zed says and cut the outer sills at top. But that would mean the A & B pillars would stick out of line by 10mm. I suppose if I cut the inner part of the sill flush with top it would fit , but I wouldn't be able to weld it.
 
Green hornet thread shows he cut str8 down the centre of the box section then clamp and reweld then itl fit
 
Ok been a while....

Been doing little bits of welding to the chassis.....

Anyways, back to the sills......

Decided to get a 3mm cutting disc and slice the top and reweld.



Still doesn't fit !!!!!

So I'm going to remove the inner part sill, fit the box section, and refit a bit of angle iron on the inside.

Might be finished by next summer !!!
 
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