Need some advice on sill welding

[Danny171]

Right, rebuild the lip it is then, will take some photos tonight and put them on,

[Bellend]

I've just had to do a huge load of welding on my girlfriends Ka. Pretty easy once you get going, I personally covered the welds in red oxide and seam sealer then fibreglass, filler and primer and paint.

MOT tester said he couldn't even see where it had been welded and there was A LOT of welding done!

[Gti_Jamo]

When i did mine I cut out the rot and reenforced the inner sill right down to the lip while I could get access to it. Got some cheap non oem sills of ebay and cut out the bits that I needed and welded them flush, no over lapping edges. Looked invisible and could be jacked up on sill afterwards.

[Danny171]

When i did mine I cut out the rot and reenforced the inner sill right down to the lip while I could get access to it. Got some cheap non oem sills of ebay and cut out the bits that I needed and welded them flush, no over lapping edges. Looked invisible and could be jacked up on sill afterwards.

What sort of steel did you use to build up the jack area?

[Gti_Jamo]

Was 1mm thick stuff. Bought it off ebay lol.

[Danny171]

As you can see the lip is totally rotted away, got some good thick steel to plate over now, just unsure on how to build the middle bit of the inner sill, to give it strength to jack from.
Suppose i am just gonna make it up as i go

[whileoceanasleeps]

how about some triangular ish pieces welded inside at 90 degrees

[Danny171]

Gonna get it all cut out, see properly what I'm up against.
Might strengthen the jack point with bit of 20x20 box section, plate over it all, then weld a strip of 35x5 flat bar to replicate the lip

[Screech16v]

35x 5  mk3 is heavy enough  , i would probably do something like this

[Danny171]

35x 5  mk3 is heavy enough  , i would probably do something like this

Great diagram, makes it look so easy!!, on my pictures, no2, you can see a central strengthen piece that comes down vertical to make the lip three pieces of steel, do you follow me?? Hard to describe
That's the bit that's worrying me