fiestaturbo.com

[fiesta_rob]

yeah half a mile from my home 18 pound for the inner arch!

that good then that where i am getting my cill from, there they are ant ford ones are they

[shaunrs]

You can either get a sill skin, about 13 quid or full sill, 23 quid heres a pic of the full sill

[fiesta_rob]

ow cheers for that info
only need a cover lol
yours is getting there now
rob

[jayrs]

You can either get a sill skin, about 13 quid or full sill, 23 quid heres a pic of the full sill

should of cut the back end off of that sill as your fitting a complete new rear panel fella

[xr2imetalhead]

nice project m8 looks like you are doing it properly. I will be keeping an eye on this thread

[shaunrs]

Jay- i left the full sill on so i could align the wheel arch height before welding, will be cutting when my qtr panel arrives

Metalhead- cheers mate been a fully qualified panel beater for 6 years now, trust me this is gona be 1 solid frst

Rob- i want too have it preped, and painted within 6-8 weeks, there are going too be no shortcuts with this one

[jayrs]

Jay- i left the full sill on so i could align the wheel arch height before welding, will be cutting when my qtr panel arrives

ah i got ya mate, for some reason i thought they were picture of work done before and the panel had been fitted now , sorry mate, i didnt refresh my self with the thread, its hard to keep track when im looking at so many, my bad

[shaunrs]

ohhh! just had a present popped through the letter box


Better get cracking, so its cut out rear reinforcer rot, and make it nice and solid again.


Then a coat of black aeorsol stone chip


Inner all cleaned and copper spray applied, high 5 primer where my structual bond is being used





then the panel cut and tacked in place, and tierd and going to bed

[jayrs]

excellent mate

whats the 2 part stuff you mixed up? your not gluing this panel on round the arch and on that edge of the B piller are ya?

[shaunrs]

yes mate this strutual panel bond, its tried and tested at thatcham its used on most modern cars now, new astra would you think the roof is actualy bonded with this same material, thats what the escribe explaines for pas125

[jayrs]

yes mate this strutual panel bond, its tried and tested at thatcham its used on most modern cars now, new astra would you think the roof is actualy bonded with this same material, thats what the escribe explaines for pas125

yeah i can belive it mate, mind you most cars now are made opf thin steel, have plastic wings and are not made to last

[Dave G fsi]

Your doing a brilliant job there mate!

[shaunrs]

Thanks dave

[zanderford]

looking good wish id have started with a whole car now

[jussrst]

ohhh! just had a present popped through the letter box

excellent job mate coming along nicely.. cant imagine how big your is door

[fiesta_rob]

looks good mate

[shaunrs]

ohhh! just had a present popped through the letter box

excellent job mate coming along nicely.. cant imagine how big your is door

lol

[jonyb4]

f**k me im liking this thread

your doing an epic job mate, gives me confedance i can sort the sills out on my mk4, not sure how you go about swapping them sills over though,

do you have to joggle the sill tot he quarter panel and filler/spray over?

heemans ZT will have her going like stink

my icon engine that, id love my 1.8 similar to that one day love the exhaust manifold especially

gonna keep my eye on this keep it up mate

[shaunrs]

Hi jony
replacing sills is not that hard realy, as long as you have some tools and some basic metal sills you will be fine.

. dont try and weld to rust, it wont weld lol
. every weld has to be a least 25-30mm apart, spot or plug, get it nice and solid
.use weld through primer, zinc or copper, copper is better more of a conductor
.make sure your innersills are solid, if not cut it out dont just wack then on

if you need any more info just ask mate

shaun

[jonyb4]

cheers mate, although im not sure what tyou mean by weld through primer and the zinc and copper bits

[jayrs]

cheers mate, although im not sure what tyou mean by weld through primer and the zinc and copper bits

its a primer paint, but largly made up of copper or zink, it stops the metal going rusty and becuase its a "metal" paint, the current of the welder passes through it to allow the weld to take place.
its works best if you flat the edge to be welded down to bare metal prior to priming with this metal primer

[fiestajames]

very nice mate looking good

[andymcd]

great work mate i like how you glue the 1/4's on, as welding them on will mean they rust true time, can you get me that glue? as thats what id like to use!

[shaunrs]

Today i thought i would start getting the sill nice and solid,
so new sill cut and lapped over qtr and a-post and gripped nice and tight


Then cut throught both panels and copper spay applied to inner sill and outer sill clean metal is a must in my appinion.



Then i put a some extra protection inside the sill with some 3m stone chip


Sill fully welded in.



I also replaced both door hinges.

[jayrs]

why ya change the hinges mate? rusted, worn out, or found a replacement door would fit the hinges?

[shaunrs]

Coudnt get the pins out, had to cut the door off.
Luckly i found a bloke selling a new door for a mk3 and offerd him a 5a for the hinges off it lol.
Dont think he knew there 20 quid each from ford

[jayrs]

[fiesta_rob]

looks good mate
but to put the sill on do you have to take the door of?
rob

[andymcd]

great work mate i like how you glue the 1/4's on, as welding them on will mean they rust true time, can you get me that glue? as thats what id like to use!

?????

[shaunrs]

looks good mate
but to put the sill on do you have to take the door of?
rob

You do realy, to do a proper job anyway.
Are they rotten or damaged?

[jonyb4]

cheers mate, although im not sure what tyou mean by weld through primer and the zinc and copper bits

its a primer paint, but largly made up of copper or zink, it stops the metal going rusty and becuase its a "metal" paint, the current of the welder passes through it to allow the weld to take place.
its works best if you flat the edge to be welded down to bare metal prior to priming with this metal primer

ah cheers jay

awsome work again there mate, looks to be a straight and true job

but anoyingly ive realised, to replace the sills are the rear you need new or the sills only cut off a rear quarter?
then joggle the new sill on, and spot weld?

do you have to drill a hole in the new panel when spot welding along the seams??

[jayrs]

cheers mate, although im not sure what tyou mean by weld through primer and the zinc and copper bits

its a primer paint, but largly made up of copper or zink, it stops the metal going rusty and becuase its a "metal" paint, the current of the welder passes through it to allow the weld to take place.
its works best if you flat the edge to be welded down to bare metal prior to priming with this metal primer

ah cheers jay

awsome work again there mate, looks to be a straight and true job

but anoyingly ive realised, to replace the sills are the rear you need new or the sills only cut off a rear quarter?
then joggle the new sill on, and spot weld?

do you have to drill a hole in the new panel when spot welding along the seams??

yeah you can trim it where the panel is, you can fit as much or as little as you want,
a joggle tool makes it a little easier than butt welding, but you can butt weld it ok.

best way is to put holes in and spot through, most joggler tools have a punch on the other side so its easier to pop the holes in

[fiesta_rob]

looks good mate
but to put the sill on do you have to take the door of?
rob

You do realy, to do a proper job anyway.
Are they rotten or damaged?

the damage it under the door and the back by the back door

[shaunrs]

looks good mate
but to put the sill on do you have to take the door of?
rob

You do realy, to do a proper job anyway.
Are they rotten or damaged?

the damage it under the door and the back by the back door

Sounds like a 5 door to me, if so the rear door will most defanatly have to be removed.
The reason i couldnt get my pins out was because they were snaped inside the hinge.

[fiesta_rob]

ow ok thanks for that info mate will have fun to fit the sill lol