Topic: Box section side sills ... anyone know a good thickness (Read 5090 times)

stuntman · « **on:** November 29, 2007, 20:11:13 »

Hello one and all,

I'm replacing my sills at the weekend with some box section steel, does anyone know a good thickness for this, is 2mm to thin? or 3mm, I feel that 5mm is to thick and very heavy!

Please help, i need to buy it tomorrow

Cheers everyone!

Andi K

Guardian. · « **Reply #1 on:** November 29, 2007, 20:20:31 »

3mm is plenty, 2 would do, but 3 would be much better without becoming stupidly heavy.
you could weld some tube runners down them too!

andyhubbard · « **Reply #2 on:** November 29, 2007, 20:46:16 »

Andi K i'd be interested in seeing them when youve'd done them as i'm thinking possibly about sliders for mine,cheers Andy.

andyb · « **Reply #3 on:** November 29, 2007, 20:55:22 »

When I did some repair work on my door sills I used 100x40x2mm box section. An almost exact fit and should take twice as look to rust thru :)

Evilgoat · « **Reply #4 on:** November 29, 2007, 21:04:04 »

Ask Niel

Serenity has bloody chunky sills that he fitted :)

Ja1983 · « **Reply #5 on:** November 29, 2007, 22:01:58 »

mines been re-built with 3mm, get some waxoyl donw them (after welding! :shock: ) and they should out-last the rest of the motor!

Niel · « **Reply #6 on:** November 29, 2007, 22:43:37 »

Quote from: "Evilgoat"

Ask Niel

Serenity has bloody chunky sills that he fitted :)

Oh yes! 4mm wall thickness, 100 or 120 x 60 IIRC, eitherway well strong, not just welded, bolted from above first to pull up tight and secure, then welded, using the trim holes in the floor and 10mm allen bolts, box section drilled and tapped in-situ... a few images under my profile too.

peasey · « **Reply #7 on:** November 30, 2007, 08:36:50 »

i agree with niel here im a huge fan of the belt and braces approach the thicker the better,all the major jobs i do are always over enginnered.i just wont tollerate the"yeah that will do for now"as now comes around a little to quickly for my liking.mind you with that said i havent done this job yet but niels way is the way i will do mine.

Guardian. · « **Reply #8 on:** November 30, 2007, 09:40:05 »

FORGOT TO SAY EARLIER, DID YOU REALISE THERE ARE CABLES RUNNING DOWN INSIDE THE SILLS!
DONT CHOP THROUGHT THEM WILL YA!

stuntman · « **Reply #9 on:** November 30, 2007, 10:30:56 »

Thanks Gaurdian,

I'm making mine from 60x120 can anyone give me a length dimension, as I'm too lazy to walk the a mile to my car on the other side of work!!

Thanks in advance everyone

Iain C · « **Reply #10 on:** November 30, 2007, 10:33:49 »

Stuntman

Any chance of taking some pictures as you go? Be interested to see how you do it...

Evilgoat · « **Reply #11 on:** November 30, 2007, 10:41:17 »

Quote from: "Iain C"

Stuntman

Any chance of taking some pictures as you go? Be interested to see how you do it...

I think Niel may have pics in his gallery. I can get pics of the finished article if you like, theres a bit o mud involved now though :)

Niel · « **Reply #12 on:** November 30, 2007, 11:01:58 »

Quote from: "stuntman"

Thanks Gaurdian,

I'm making mine from 60x120 can anyone give me a length dimension, as I'm too lazy to walk the a mile to my car on the other side of work!!

Thanks in advance everyone

1500mm IIRC and trim to suit~120-150mm depending on pref's.

Steve ray · « **Reply #13 on:** November 30, 2007, 18:32:09 »

50mm sq boxsection on mine, 5mm thick ......... can't be too careful

stuntman · « **Reply #14 on:** December 01, 2007, 08:25:59 »

Hello one and all, I was told 60x1201400 - 100mm to short, so I bought that and found i was to short, I'm off this morning to try and get some more, I will take piccies as I go!

Hopefully it will go ok

muzzer · « **Reply #15 on:** December 01, 2007, 09:37:06 »

I need to do mine as I found hole in the drivers side so I have tooke my sliders of and am just waiting for time to do it so photos would be nice.

stuntman · « **Reply #16 on:** December 01, 2007, 19:40:21 »

Well side one done, it's taken for ever and I've burnt my hand, note to self ALWAYS wear gloves :), I take it back, 1400mm is ideal, I'll post pics tomorrow night or throughout the week, I'm pretty pleased with it but I've had to do alot of other welding. I found I diidn't really have a passenger footwell

Oh well, I'm off to the shower!

Disco-Ron · « **Reply #17 on:** December 01, 2007, 19:51:17 »

The pics will be interesting..... my sills are looking a little tired, and the sliders just get full of mud when i get it dirty.... so maybe this could be the solution...... i could add nice tree bars aswell then eh!!!

Niel · « **Reply #18 on:** December 01, 2007, 22:13:31 »

Quote from: "stuntman"

I found I diidn't really have a passenger footwell
!

About normal, BTDT eh EG

stuntman · « **Reply #19 on:** December 02, 2007, 18:53:45 »

DONE - DONE - DONE - DONE!!!!!!!!!!!!!!!!!!!!!!!

Pictchoors will follow this week!

Steve ray · « **Reply #20 on:** December 02, 2007, 20:01:35 »

I've painted mine with black "plasti-coat" spray paint - gives a great finish and is easy to touch up

stuntman · « **Reply #21 on:** December 03, 2007, 08:10:53 »

Thanks steve, 4 coats of thick hammerite have smoothed things up!

I really need to take the rear body mounts now

Oh well another week of welding, and my MOT is due in a week or so :?

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AuthorTopic: Box section side sills ... anyone know a good thickness (Read 5090 times)

Guardian.

Guardian.