Project Lemondrop

[sprint95m]

The sill structure on a Dolomite is of a popular design consisting of 3 main components, ie inner, centre and outer.
The curse to carrying out repairs is encountering previous "MOT" repairs (where plates are welded over rusted holes).
Attached are photos that I hope are helpful, Ken.



Firstly, I trial fit the outer sill (using self tappers along the top edge. This is a TDC supplied sill which is a good fit.
Photo shows back of the OS sill.




These photos are views of the sill structure with the outer cut and pulled down to reveal the inner structure.





To form a box section for reinforcement at the jacking point a plate is welded between the inner and centre sills (at right angles). It is just visible (highlighted). The lower section (where the jack meets the inner sill) is also reinforced.

Use decent sheet steel for patches (1.2mm thick or 1.6mm thick (my choice)) and don't cut out too much all at once.
Judging from your thread so far, these repairs shouldn't present too much difficulty, but they are time consuming.
Hope this is helpful, Ken.

[Purplebargeken]

Thanks Ian, that is indeed helpful. I've started making some templates and have cut the first of the repair pieces from decent guage steel.

I must say it again. The Club sill is brilliant. If yours needs doing please don't buy any of the cheaper stuff out there, it really isn't worth it. Brilliant bit of kit

[Nathan Mwk 627G]

Heres some photo's of Kens Sill section that needs repairing and also the Club repair panel in place!!

Club sill do look a really good fit...bargain at £22 a side!!!







Nathan

[Purplebargeken]

Cheers Nath

[1300dolly]

Good work there ken, how many people actually use the original jacking points to jack up their dolly?
I use the subframe or on the rear the joint where the wisbone meets the rear beam.

[Purplebargeken]

Haven't had much time to do anything on LD thus far. However, she is now insured FC via FJ for £91. Tis the cheapest I could get. Next cheapest was 109.00 from Adrian Flux. Most of the insurance bods couldn't match FJ's quote as it's recognised as being about the lowest around.

Anyway, in the absence of any more snow, I hope to get the mig warmed up and the sill on tomorrow. Piccies to follow. Fingers crossed.

Ken

[Dollyboy]

great work m8.

assuming club sills are those from the al nicholas supply chain, they are the best value you'll get, absolutely no doubt

[Purplebargeken]

They are indeed the sills from Alun.

Ok, more updates. Spent today repairing the inner sill. New metal let in and I must say that I am pleased with the result. It's neat'ish and strong.... that'll do for me.

Just need to trim the rear wheelarch section that was welded in to shape and then weld the sill on. Found a couple of holes in the rear inner wheelarch, might just fill them just for now as they aren't structural. Tomorrow will see me sorting out the no plate light and the sidelight. Back box has small hole in it, will weld this for the time being. I have a spare in the shed somewhere. Need to clean the calipers as the n/s front is binding slightly.

On a fun note, I trashed a newish 'blinged up' 4x4 away from the lights on the A10 Oh did I laugh

I might also replace the seats tomorrow and do the leaky rocker cover gasket. Not a drop of coolant is escaping now from the thermostat housing.... result I have yet to replace the rear shocks and springs and am hoping to try and get that done before the MOT. If the weather holds out I will aim to do the mot maybe by the end of the week... fingers crossed.

Will check the pics that I took and will ask Nath if he could post them for me if they are up to scratch.

Please bear in mind that the repair section had just been cut out and hadn't been cleaned up or anything. The rust on the inner sill bits was ground out and the panel was just trial fitted. Looked much better when welded in

Thanks Martin.

Cheers

Ken

[mbellinger]

Good work Ken - keep going mate. These TC's are lovely cars - you will love it.

[Nathan Mwk 627G]

Please bear in mind that the repair section had just been cut out and hadn't been cleaned up or anything. The rust on the inner sill bits was ground out and the panel was just trial fitted. Looked much better when welded in

Must say Ken your really cracking on with this now, I think you have overtook me for 1st in this race

She's looking cracking mate......it will always look worse before it gets Better!!

Sterlin work mate..1st class keep it up!!

Photo of the work!!


what said hello to ken when the sill was taken off


repair section made up


Trial fitted to the car before the welding comences!!

Nathan

[Purplebargeken]

Had a bit of a stress out tonight, even tho not much at all to be done on the car, still felt like crap. Pending collection of fwd's getting to me and other bits and pieces as well. Normally able to cope but just not today. Major headaches again today as well

Felt like sh1te and struggled today. Made a list and feel a bit more in control. Bloody head injury leftovers makes it very difficult at times to think clearly and planning ahead in perspective is problematic sometimes. Not my usual self today at all

Self pitying whine now over

List for MOT

Clean caliper... n/s
Fix sidelight wire
Fix no plate light
Weld on outer sill
Clean up hole in n/s outer sill and weld patch
Fill little holes in rear wheelarch

Will get my s##t together tomorrow and cross off some items hopefully.

Ken

[Purplebargeken]

Ok, feeling a fair bit more focused today. Have sorted out the wiring. I replaced the earth wire from the n/s sidelight/indicator unit. The old one was pretty goosed and needed doing really. This made no difference to the indicator but the sidelight was happily illuminating. Hmm. Cleaned up all the connections and wiring on that side of the loom (by the headlight) just for the sheer hell of it. No difference. Bugger.

Went to the rear light cluster. Fixed the no plate light which was just down to a loose connection. Sorted.

Checked the bulbs in the n/s cluster...... indicator bulb knackered. New bulb and relocated the earth wires, with a new connector...... all sorted Wipers still wiping, just had to adjust the aim of the washers slightly. Replacement sealed beam headlight now given up the ghost, but I have a replacement.

To do tomorrow:

Try other back box... maybe.
Rear wheel arch patch up.... filler.
Fit headlight

Day after (maybe)
Weld on new sill, one patch to n/s sill, free off and clean slightly sticky caliper (s).

Phew. Then, maybe MOT if nothing else turns up

[Purplebargeken]

Oh well, despite best intentions all I did today was:

Tightened the fan belt (ign light still glowing)
Cleaned the earth connections in the engine bay
Lowered the drivers seat (more headroom now )
Fitted lovely stainless steel screws in the boot trim panel
Secured the battery and battery connections properly
Cleared the mess out of the car and the boot

Tomorrow will see me taking the car to Steam Engine Mate to do the rest of the bodywork and the bloody sticky caliper. I don't care if my bloody head explodes..... the work will be done!!! Oh and sort out the back box.

See you tomorrow

Ken

[Purplebargeken]

Ok, the sill is on

The rusty areas on the n/s sill have been ground back and prepped for welding tomorrow. Found a bit more bodywork to do. Nothing major. Will hopefully get it sorted tomorrow. Gave S.E.M a hand sorting out a 1989 Fiesta.. new bumper, headlights and wishbones, so that took a bit of time. I help him, he helps me. Works out in the end. Replacement outer sealed beam headlight fitted.

Getting there... slowly.

Ken

[Purplebargeken]

Ok, worked in S.E.M yard from 10:30am to 19:00 today, don't worry, took it easy.

Bits done today:

Welded patch on n/s sill, patch on rear inner o/s wheelarch, o/s wing lower (temp) repair section (home made repair panel... too skint to buy the Club one, sorry. I will buy one later).

Welding to do tomorrow: front wheelarch patch (2" x 2"). That's the welding over and done with then. Ground out the cacky bits from the front valance.

Removed old holey back box, fitted used back box found in the shed. Job done, lovely. Wipers still wiping.

Next..... cosmetics, to include a tidy of the underneath of the car, mostly around the back end for now and some cosmetic filling around welded bits. Will do the same treatment underneath as per the wheelarches.

Clean calipers... can wait for a wee while. Fit replacement seats, fit period radio and speakers... fit arial. Fit new thermo switch thingy. Fit new fanbelt and ? alternator. Give the car a service.

Sill fitting has shown up a bit of a boo boo on my part. I think I needed to pull the sill top lip more away from the body of the car as the sill fits lovely a both ends but 'comes in slightly towards the middle. It looked fine when it was being done, just noticable now tho. Not the end of the world. I know how to improve it for the other side. Shame

Getting there .