SOS - Save my sill...

Bodywork, interior and exterior trim and glass, bumpers, etc.
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simon.williams
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SOS - Save my sill...

#1 Post by simon.williams » Mon Jan 20, 2025 7:07 pm

Hello,

I haven't got the angle grinder out yet, but the drivers side "bottom plate" of the sill is totally gone at the front jacking point, and it looks to be going at the back as well. Inside is not very pretty either although there might be some solid metal further up that could be welded to. The wheel arches at sill level have some holes. The outer sill looks very solid apart from some small holes in one location.

The outriggers and all the floorpans look OK, just surface rust.

I imagine that just cutting out visible bits and trying to patch everything up with new metal will be false economy?

Is there a "2.5 sill replacement for dummies" document anywhere? I've never done major metal surgery on a car but I have a small gasless mig, would like to have a crack at this and I am not in a big rush. It would have to be done in my garage. I would like to avoid chopping the bottom of the wings off if I can (is this possible?).

I know there are three sills - but thats as far as my knowledge goes. How they go together is as yet a mystery.

Thank you in advance for any pointers!

Simon
Attachments
rear wheel arch.jpg
outer sill small holes.jpg
gaping holes.jpg
front wheel arch.jpg

Charles H
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Re: SOS - Save my sill...

#2 Post by Charles H » Tue Jan 21, 2025 8:47 am

You will need to cut off the bottom of the wing to give the strength back to the structure. The sill runs behind the wing. It is possible to fabricate the parts you need but it takes a long time and a lot of effort. Lloyd Reed does panels these days to OE spec and may be cheaper in the long run. You could possibly use parts of the panels he supplies if your car is not too bad, however what you see is usually only the tip of the iceberg. Good luck.
Charles Harrison
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simon.williams
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Re: SOS - Save my sill...

#3 Post by simon.williams » Sat Jan 25, 2025 10:07 pm

Thanks, Lloyd is now sorting me out with all the sill parts and also sent some notes on how it’s done. I will make my own notes & photos on how it goes! Fingers crossed.

Mike Stevens
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Re: SOS - Save my sill...

#4 Post by Mike Stevens » Wed Jan 29, 2025 12:49 pm

Hi Simon,

Glad to see that you are getting some bits together. I can share some of my sill repair photos if you'd like. It should give you an idea how it all fits together.

Cheers,
Mike.
(South Oxfordshire)
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(1949 LandRover which is now back to its original light green!)

simon.williams
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Re: SOS - Save my sill...

#5 Post by simon.williams » Fri Jan 31, 2025 9:14 pm

Yes please Mike, that would be great. I do want to get it right. I also have to repair/reinforce two of the drivers seat rail bolt-holes if anyone has done these.

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