Replacing Outer Sill Panels?

[Lukey-KE20]

I've searched for this and have found a fair bit of Google info - but nothing here.

Firstly, a bit of background. I have 3 KE20's at present. I'll eventually have 2 - one track car for some club events, and one nice street car for my son, when that time comes.

Car 1 has been stripped back to a bare shell, which has revealed some pretty bad body work, including mangled rear guards and a roof that has been walked on. This shell will be crushed soon. Car 2 (the track car) has some rust and damaged outer sill panels but is otherwise much straighter. The sills on Car 1 are straight and apparently rust free.

This is the same situation for the plenum panels in front of the windscreen. Car 1 is straight, car 2 bent by bonnet hinges.

What I'd like to know is the feasibility of removing the sill and plenum panels of Car 1 and replacing on Car 2 - or am I better of trying to get some fabricated ?

Thoughts appreciated.

[o_man_ra23]

Personally I would fabricate for the sills. The sills on car 1, when removed, will reveal the rust inside the sill. This rust wont have reached the outside just yet. If its a track car, I would just get into it with some 1mm high carbon plate steel and a mig (dont get the crappy rusting steel used in holdens n fords, and gal steel is a PITA). As for the plenum, im not exactly sure about the rollas, but if they are the same as the RA40 celicas, they would probably be best off cut and plated, with 1.5mm plate around the hinges. They tend to rust down where the base of the hinges are, and you will probably find inner rust in car 1 when you cut it out. If looks arent a problem, and your not a complete numpty with a welder, then DIY FTW.

Cheers, Owen

[Lukey-KE20]

Thanks Owen

I've rung around and it seems that fabrication might be easier said than done. I live in Bathurst so I might have to go to Sydney get them done. I'll cut out the panels on the wreck anyway and see what they're like. Anyone with any recommendations for fabricators?

I started removing the sills for the track car this afternoon. Picked up an air cut-off tool and proper drill bit then got stuck into it. The air tool is so much better than an angle grinder. It gives far more control.

I've drilled all the spot welds and begun cutting the sheet metal in the apropriate spots. I might do write up on the process and post some pictures too.

Thanks again
Luke

[o_man_ra23]

I fabricated my own using new plate steel, vice grips, multi grips a 32 oz ball pein hammer and a towbar as an anvil... came up pretty reasonable, and my RA23 sills were munched.

Cheers, Owen