Well. After all my work I'm pretty deflated as the inner-sill is back in but something's not right
I've been super-careful about alignment and measuring [plus spent a lot of time yesterday making sure the sill was straight on all planes as welding the long strips on to renew the flange(s) obviously required a long line of weld and - despite doing it in several sessions - there must have been some distortion due to stresses/strains/heat and I dressed this all out] and was constantly checking the bit at the end where the top of the sill meets the outrigger meets the door-pocket.
There was no more checking I could possibly do so I welded the sill in today and now, with hands free, checked again and again why there's a gap between it and the outrigger. Or if you align the outrigger with the sill there's a gap between that and the door-bin.
I could re-attach the outrigger then force the sill up to meet it but if the sill is bent then it won't meet the centre-sill properly.
I was hoping to get that spot & plug-welded in today. I dug-out my spot-welder the other day and spent a few hours wiring it directly into the mains (30amp fuse) and making sure the arms and electrodes were adjusted properly and had nice clean tips on them.
It's working fine and so much quicker-easier to do than normal welding.
Anyway I can't proceed any further till I work out how to get round this issue. It's probably got something to do with the sagging/jacking issue detailed recently. It looks like something has been jacked a 1cm too high up but that's unlikely as the floor-support is in exactly the same place it was before and the panel below it is deep and vertical and can't really bend upwards.
I'm going to need to do a lot of measuring within the car and on the half-Imp to see if I can find any answer.
The whole lot might need to come back out and start again but I think that's unlikely.
Basically I decided to abandon it early this evening and go home and watch the Croatia-Scotland game - then realised that's on tomorrow
inner-sill back in
rear-end tied in
if outrigger is aligned with sill (orange dots) spots from outrigger to floor-support don't meet
also rear of outrigger should follow horizontal plane of sill
this is better illustrated in this pic
also when outrigger and sill meet outrigger is too low on door-pocket
if outrigger is up at original position with door-bin and floor-support panel it doesn't meet sill
I've been super-careful about alignment and measuring [plus spent a lot of time yesterday making sure the sill was straight on all planes as welding the long strips on to renew the flange(s) obviously required a long line of weld and - despite doing it in several sessions - there must have been some distortion due to stresses/strains/heat and I dressed this all out] and was constantly checking the bit at the end where the top of the sill meets the outrigger meets the door-pocket.
There was no more checking I could possibly do so I welded the sill in today and now, with hands free, checked again and again why there's a gap between it and the outrigger. Or if you align the outrigger with the sill there's a gap between that and the door-bin.
I could re-attach the outrigger then force the sill up to meet it but if the sill is bent then it won't meet the centre-sill properly.
I was hoping to get that spot & plug-welded in today. I dug-out my spot-welder the other day and spent a few hours wiring it directly into the mains (30amp fuse) and making sure the arms and electrodes were adjusted properly and had nice clean tips on them.
It's working fine and so much quicker-easier to do than normal welding.
Anyway I can't proceed any further till I work out how to get round this issue. It's probably got something to do with the sagging/jacking issue detailed recently. It looks like something has been jacked a 1cm too high up but that's unlikely as the floor-support is in exactly the same place it was before and the panel below it is deep and vertical and can't really bend upwards.
I'm going to need to do a lot of measuring within the car and on the half-Imp to see if I can find any answer.
The whole lot might need to come back out and start again but I think that's unlikely.
Basically I decided to abandon it early this evening and go home and watch the Croatia-Scotland game - then realised that's on tomorrow
inner-sill back in
rear-end tied in
if outrigger is aligned with sill (orange dots) spots from outrigger to floor-support don't meet
also rear of outrigger should follow horizontal plane of sill
this is better illustrated in this pic
also when outrigger and sill meet outrigger is too low on door-pocket
if outrigger is up at original position with door-bin and floor-support panel it doesn't meet sill