sill box section size

[bodgeitjo]

hi guys im back havn"t been on here for a while gone to the dark side and bought a jeep but i would"t take it off road dont even like it on road .............any way went out and bought a pile of rust with an engine :lol: so got to get the welder out what im after is what size box section would i need to totally cut out whats left of old sill and replace with box cheers       jo

[clbarclay]

The sills is approx 100*60mm plus the spot welded lip sticking down below this. 100*50 or 120*60 are common sizes and a 3mm wall thickness should be fine. Mine are 100*50*3 and have held up fine so far. You will need approx 1.4m each side.

You will also need some metal to make new body mounts on the back of the sills if your chopping the whole lot out. I used some 3mm plate to replicate the originals.
I used some 18 and 16 swg sheet to replace the rest of the floor that got cut out.


Before you start, pic a load of datum points and measure between them and then only cut out one sill at a time, so that when you come to welding it back together you can make sure its all in the right shape and the doors fit as well (or badly) as the did before.

[pinkrover57]

Hi Jo,

I did my rangie which is similar to your disco, 120x60x5mm secrtion, (it was free, 3mm should be fine). couple of tips;

1.   cut the original sill  along the bottom to leave you an upside down channel, that way you don't need to make new body mounts and it easier to weld.

2.  cut out the strengthing ribs inside the sill, you dont need them

3. jack up the box section , if you drill a couple of small holes in the floor , one at the front and the back abovethe sill, you will be able to see if the box section is fully up into the sill. You can also puddle weld     the sill and box together using these holes.

good luck.. :D

[bodgeitjo]

cheers :lol: