Angelo Graham wrote:
>
> 1. Is it possible to replace the inner sills and leave the outer sills
> (rocker panels) in place or to salvage these?
>
I'd say it's possible, but maybe not worth it. You'd have to cut out a
lot of
spot welds, and new outer sills are about the cheapest panels on the
car.
> 2. What does the outer edge of the floor fasten (weld) to - the inner side
> of the inner sill?
>
Yes... If you see a good inner sill, it has a narrow shelf on the inner
face.
The floor rests on the shelf, and the vertical edge of the floor and the
top vertical edges of the inner and outer sills form a spot-welded
sandwich (4 ply- the inner sill is made of two pieces). Usually
replacements
are seam welded along the top of the sandwich and tack or seam welded
from
below where the floor meets the shelf.
> 3. The joint at the top of the rocker panels, the verticle edge dropping
> to the floor - which panels meet here? Is it formed by the top of the
> inner sill and the outer sill welded together?
>
See #2
> 4. Should I just bite the bullet and cut everything out - sills, floors,
> etc and start all over?
>
> In my case, most of the panels, including the floors look repairable, no
> significant rust, except for the inner sills. Would be nice to be able to
> salvage some of them. Doing my own MIG welding and panel fitting.
>
It's your call. You might find the old metal isn't as good as it
looked.
Outward appearance is always the last thing to go.
On the other hand, the more you leave attached, the easier it is to keep
everything aligned, and floors aren't cheap (and can be covered with
carpet).
Take a good look at your "A" and "B" posts, and maybe weld a chunk of
metal
across the top of your door openings. The capping will cover any mess
you
leave behind.
Good luck. I went through the full replacement of posts, sills, and
floors
on TS39550 and it was a pain getting the old metal out, but I had no
choice.
Also, I had no good body alignment to maintain. Even the new parts had
to
be modified, but welding with shiny new steel is certainly easier (and
leaves
fewer holes).
Dave
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