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Dynorog
V4 Fanatic

United Kingdom
249 Posts

Posted - 20 Feb 2021 :  08:46:19 Show Profile Reply with Quote
When new sills are fitted is it OK for MOT purposes, to plug weld instead of the original spot welds or is it necessary to weld all along the seam as you have to for a patch repair?
Cheers

Dynorog

UK_Sub
V4 Guru

United Kingdom
2555 Posts

Posted - 21 Feb 2021 :  18:00:40 Show Profile Reply with Quote
I plug welded my sills, and seam welded the ends. Apparently the MOT man likes them to look original, rather than welded along all 4 edges. Less likely to distort too.
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UK_Sub
V4 Guru

United Kingdom
2555 Posts

Posted - 21 Feb 2021 :  18:05:17 Show Profile Reply with Quote
And make sure the holes you drill in the sills are at least 8mm wide (and a similar distance apart as the spot welds, approx 40mm) - to give the weld a chance to latch on to the inner and outer sill.

I was told one way to keep the new sill tight to the inner sill (during welding), was to use self tapping screws through the holes you drilled, removing a screw at a time, plug welding the hole and moving on to the next...
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Dirtbiker
V4 Guru

United Kingdom
1060 Posts

Posted - 21 Feb 2021 :  19:23:10 Show Profile Reply with Quote
Hi Roger,
Just my opinion so might be worth checking the mot testers handbook but I plug welded mine and they look original. Every time I take it for an mot they all stop what they are doing and have an admiring look. This could be because they were expecting a crusty pile of rust based on seeing the bodywork...
I will try and update the photos on my thread for the 96 as I showed what I did step by step.
Cheers

Edited by - Dirtbiker on 21 Feb 2021 19:23:54
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Dynorog
V4 Fanatic

United Kingdom
249 Posts

Posted - 23 Feb 2021 :  16:02:59 Show Profile Reply with Quote
Thanks Simon and Gareth for your responses, much appreciated.
So I will plug weld and seam the ends. I had better practice doing the plugs first though.
The ones I've done in the past come out a bit sort of half baked... bit like me really.
I have a look at your project as well Gareth.
Thanks again.
Cheers


Dynorog

Edited by - Dynorog on 23 Feb 2021 16:04:36
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Dynorog
V4 Fanatic

United Kingdom
249 Posts

Posted - 23 Feb 2021 :  18:52:50 Show Profile Reply with Quote
Just looked at you 72 project Gareth - Photobucket are real Bar stewards aren’t they!

Dynorog

Edited by - Dynorog on 24 Feb 2021 08:13:34
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Dirtbiker
V4 Guru

United Kingdom
1060 Posts

Posted - 23 Feb 2021 :  19:31:03 Show Profile Reply with Quote
I’ve got the photos on Flickr now which we pay £50 ish a year for. Seems alright really when you think how much it used to cost to develop a roll of film. I have started changing the links, I’ll try and do the ones for the sill for you.
Cheers
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Dynorog
V4 Fanatic

United Kingdom
249 Posts

Posted - 24 Feb 2021 :  08:15:01 Show Profile Reply with Quote
Thanks for the updated photos on 72 project Gareth.
Cheers

Dynorog
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Dirtbiker
V4 Guru

United Kingdom
1060 Posts

Posted - 24 Feb 2021 :  22:40:56 Show Profile Reply with Quote
I have just added a few more showing the sill being welded in. Thought I best get them done or you would have your sills fitted before I got round to it!

Next time I wouldn't plug weld the jacking points. They should be seam welded but not all the way around and I think that would be nicer. Having said that I would be tempted to leave them off and I probably wouldn't bother with the small mudflap bracket at the rear of the sill. Not only is it a rust trap but in eight years or so since making the bracket I have never attached an actual mudflap...

Cheers
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Dynorog
V4 Fanatic

United Kingdom
249 Posts

Posted - 02 Mar 2021 :  14:49:05 Show Profile Reply with Quote
Thanks Gareth.
Not fitted the sill yet. I got a bit out of sync and was doing bits here there and everywhere. There is so much to do but I get bored doing the same thing day after day.
Despite this I decided to concentrate on cleaning up the whole of the underside of the car before proceeding with the sill. So then my 29yrs old heat gun packed up and I ran out of white spirit.Back on it again tomorrow though.
Cheers

Dynorog
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Dynorog
V4 Fanatic

United Kingdom
249 Posts

Posted - 13 Mar 2021 :  14:57:25 Show Profile Reply with Quote
Nearside sill now on. See Dennis Project
Cheers

Dynorog
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andydeans3
V4 Guru

United Kingdom
1994 Posts

Posted - 14 Mar 2021 :  11:38:01 Show Profile Reply with Quote
quote:
Originally posted by UK_Sub
I plug welded my sills, and seam welded the ends. Apparently the MOT man likes them to look original, rather than welded along all 4 edges. Less likely to distort too.


I had a pair of galvanised Malbrad sills fitted a couple of years ago, and the welder plug welded the outer edge, but also seam welded them all the way round, to try and seal them to help prevent moisture getting into the cavities.
He used weld through zinc primer.
When it was all done, I sprayed POR 15 into the cavity sections, using a long lance. Tons of it, followed by tons of Bilt Hamber cavity wax.
I replenish the wax at least once a year. I also did not refit jacking points. They're just moisture traps. I shaped the sill profile out of a block of wood for jacking.
Never had any issues with the MOT. Passed 1st time again this year, with only a couple of silly wee advisories.

Andy

1978 LHD SAAB 96
1978 MGB Roadster
2008 LHD "Classic" Renault Twingo
1991 Nissan Figaro

Edited by - andydeans3 on 14 Mar 2021 11:39:03
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