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good morning this morning - first sill box section cut to length, end caps fitted, front floor support and first mounting bracket fitted.
Cleaning up and fettling required by Friday. Plus ordering more parts for offside.

pics to follow, i think ;).
 
Great morning.

Well, sort of :(

My sincerest apologies to MHM for my 100% certainty that turned out to be 100% wrong :oops::(

But we were cookin on gas with the welder today :D

Cut the 120X60X3.6mm box section cut to size (1450mm) and the ends capped off.

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Fitted the floor stiffener on to the end cap.

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And look at that, more penetration than a porn hub movie :D

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OK, I have very mixed emotions over this, yes it was some very nice welding............

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Mmm..... Yeah then comes the revelation, I used the wrong measurement and welded it up 60mm too far back, what a prick :mad::mad::mad::mad:

Yeah yeah, I know, but when you get it in your head, it's there and I went with my pig headed "I'm right" feeling and sadly MHM has a little bit of cutting and grinding to do to remove this body mount and buy a new one to, maybe, supervise me welding them on :oops::rolleyes:

Gonna keep plugging away and trying to get it right as we go :)
 
My sincerest apologies to MHM for my 100% certainty that turned out to be 100% wrong :oops::(
Mmm..... Yeah then comes the revelation, I used the wrong measurement and welded it up 60mm too far back, what a prick :mad::mad::mad::mad:
Gonna keep plugging away and trying to get it right as we go :)

Stuff happens, after this long I'd guess @The Mad Hat Man and Tuftee won't worry about a bit of extra time .... ;)
 
and more - the front end closure panel/floor support and modification :)

Scurfing off surplus weld
NS Sill front closure panel-1.JPG


Removal of surplus flanges
NS Sill front closure panel-2.JPG


Modification of lower flange to reduce entrapment of road debris.
NS Sill front closure panel-3.JPG


Acid etch primed ready for body mount fitting.
NS Sill front closure panel-4.JPG


You can see where the outside lip and the short bottom lip have been removed as no longer necessary, and the main bottom lip has been bent downwards to reduce trapping road debris. It has been left in place as, I believe, it aids stiffening.

Cant beat a bit of stiffening combined with good penetration :eek: :D
 
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and @dieseldog69 doom ;). Removal of front body mount.

Stage 1 - removal of old mount.
NS Sill Body mount removal -1.JPG


Stege 2 - removal of side flanges.
NS Sill Body mount removal -2.JPG


Stage 3 - Cleaning up of surface, ready for etch primer.
NS Sill Body mount removal -3.JPG


As can be seen - really good penetration of welds :)
 
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is the floor support at the back end of the sill i.e. rear? I'm thinking there isn't much on mine as far as floor support goes!
 
is the floor support at the back end of the sill i.e. rear? I'm thinking there isn't much on mine as far as floor support goes!
No. There are 2 at the front of the sill acting as a sill closer and another smaller one attached to the front of the front body mount. This smaller one usually fits inside of the sill, creating a collosal mud trap.
 

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