[Spridgets] rust in outer sill

[Bud Osbourne]

Andy,
Depends on how you define "major tear-down", and how original you want
it to look.  If it's done wrong, it'll stick out like the proverbial
sore thumb.  The key consideration is how you plan to connect the outer
sill to the A post, and the rear quarter (the seam between the door
opening and the rear wheel arch).  Since both seams are structural
elements, they are important.
I now pre-fit and attach the lower sections of the A post and rear
quarter to the outer sill, before attaching the outer sill to the tub.
Then, you will have two horizontal butt seams to make....yeah, you CAN
lap them (easier, by far), but it's tidier with a butt seam.
On my latest project, I got the butt welds laid down so beautifully that
they hardly needed any filler to smooth them over.  Unfortunately, the
arc of the panel, from top to bottom, was interrupted ever so slightly
by the new section that it shows, when viewed from the right angle, and
I'm going to have to re-configure both areas over the up-coming winter.
As far has having one of the local boiler makers do your
welding....probably not a great idea, unless the guy has done it before.
Welding plate & structural steel is far different, and FAR easier than
welding thin, very easily warped automotive sheet steel.  
Bud Osbourne

-----Original Message-----
From: spridgets-bounces+abcoz=hky.com at autox.team.net
[mailto:spridgets-bounces+abcoz=hky.com at autox.team.net] On Behalf Of
Andy Webster
Sent: Saturday, July 12, 2008 11:50 PM
To: spridgets; spridgets at autox.team.net
Subject: [Spridgets] rust in outer sill

Greetings,
I have some  rust in  my LH-outer sill, along the bottom edge at the
front.
It's more than just fizz really and a 2 inch x 3 inch section is
starting to
look particularly nasty.
I am wondering whether the outer sill can be replaced without a major
teardown, or whether a section can be repaired without relying too much
on bog
(bondo) to do it.
Having never done it before and this car having had several previous
owners....there is every chance that it already contains untold amounts
of
filler...I guess a magnet could tell me.
I'm no welder but I work with boiler makers who are, and are open to
payments
in cartons of beer.
If any experts would care to see a pic and offer advice, i can email a
photo
or two.
cheers
Andy