Welding advice - sills and crossmember

[GeorgeHurst]

Hi there,

I've uncovered some moderate rot under the driver's side sill on my saloon and need some advice on how to treat it. I don't know whether to cut out a small section and weld a plate over it, or to cut the whole underside of the sill out and weld in a new repair panel. There is a hole and loads of surface rust on the sill end of the crossmember also, so wonder if I should cut this bit out and replace or plate.

Please take a look at the photos below to see what it's like. I've never undertaken this sort of repair before so don't quite know where to start... any advice gratefully received...

Driver's side sill, showing holes directly above cross member:
[frame][/frame]

End of cross member, under driver's sill:
[frame][/frame]

Condition of sill at A-post:
[frame][/frame]

[GeorgeHurst]

I also have a big 'rust crack' on the B-post, half way up, by the bottom of the windows. This was repaired about 6 years ago by someone. The crack spreads right around the b post into the inside of the car, and is about 3 inches long on the exterior face.

Can I grind this out a bit and then fill with weld, or should I replace the area from a donor car?

Many thanks
George

p.s. pics to come as I can't seem to upload them at the moment...

[GeorgeHurst]

[frame][/frame][frame][/frame]

[bmcecosse]

Both lots look nasty.......... You can/should just remove the jacking points from the ends of the crossmember - and that will give better access to cut away the rot and weld in new metal in the sills - just cut/shape bits of steel as you need them.
The B post crack......I suggest you ask Jon at JLH for advice on how best to tackle that - he's banned here - but easily available on the other Forum. And - you can see Kate's car now all properly repaired by JLH after it's previous 'restoration' ( ) , and looking very nice indeed!

[Dryad]

And - you can see Kate's car now all properly repaired by JLH after it's previous 'restoration' ( ) , and looking very nice indeed!

I looked on the other forum but couldn't find it! Have you got a link for it?

[bmcecosse]

Here you go - can't imagine how you couldn't find it...........
http://mog.myfreeforum.org/about2010.html

[Dryad]

Thanks, BM. Yes, I tried looking under Long Term Projects, like the fool I was!

[cadetchris]

looking at your pics of the B post, thats exactly where mine has cracked, on both sides. it hasnt been repaired, but i am at bit of a loss what to do with it.

[DAVIDMCCULLOUGH]

The B post is a common problem, it happens if your door doesnt line up proper and you have to slam it shut!! I had to repair both sides on my blue minor. It a window out job, what I did was clean it all up to bright steel, weld it up with oxy acetelaine and as its a weak spot put a narrow plate over the weld and seam weld it on as well. That was about 9 years ago and its still ok even after everyday use for most of that time.

[GeorgeHurst]

Thanks very much for the help on this everyone, glad to know that the sill can be patched and that the B-post crack is not just on my car! I have the car stripped to a bare shell now so access for everything should be nice and easy.
Cheers, George