TA22 Sill Spot Welds

[Pattymac]

Hey guys, replacing the sills at the moment and I'm wondering where the outer sill actually ends? Iv'e undone every spotweld that I can see barre one I think assuming they're only located top and bottom. Now, where the sill runs under the door jam/rear quarter, is this fixed in place somehow? It doesn't look like it's gunna budge. Am I going to have to make some cuts? I was hoping I could get away with simply unstitching it and it would come out in one piece.

I've marked a red line where I was thinking I would have to cut, you can see what I mean by where the sill meets the jamb/rear quarter. I've also included a pic of the replacement sills if it helps at all.

[Pagie84a]

At the rear the quarter part overlaps it by a bit. Take the rear section off too since its toast aswell itll be easier. at the front that rounded off part is part of the sill too. Im surprised it isnt rusted too there wasnt anything left of one of mine

[Pattymac]

So I should be able to make a cut up the front and take the whole thing out? And is the rear overlap attatched somehow like a sealer or anything?

Don't worry the other side rounded part is rooted I'm not that lucky!

[Pagie84a]

Yep cut it. Dont know how it was attached I just cut it off and chucked it without lookin

[Pattymac]

Alrighty looks like I gotta grow some balls and start cuttin! Do I have to worry about cutting through into the inner sill at all? And do you have any pics of your rounded sill end patch? Just not sure what to do with the captive nut situation.

[ToyTA22]

Pattymac. You will find, if still original sill,there is I think two gussets welded in between inner and outer panels. unluckily don't have photos with old sill removed.

[Pattymac]

Sorry but what is a gusset? I had a peek through the opening in the rear door and there was a bracket of sorts in there which I didn't expect is that what you are referring to?

Also I'm not sure how to explain this, but originally, I thought the sill was simply spot welded top and bottom from the exterior of the car, and I'd have to cut some sections out, but from looking at it, it appears there is a bunch of spotwelds in the interior side which would allow the entire sill to come away yes? Besides the front knobby end of the sill, I'm planning on cutting it there and rejoining it.

[ToyTA22]

Sorry but what is a gusset? I had a peek through the opening in the rear door and there was a bracket of sorts in there which I didn't expect is that what you are referring to?

Also I'm not sure how to explain this, but originally, I thought the sill was simply spot welded top and bottom from the exterior of the car, and I'd have to cut some sections out, but from looking at it, it appears there is a bunch of spotwelds in the interior side which would allow the entire sill to come away yes? Besides the front knobby end of the sill, I'm planning on cutting it there and rejoining it.

gusset is term for reinforcing plate or bracket, gives structural strength at that point. The bracket you mentioned is what i'm talking about. There is two of those, out of memory, one is roughly inline with rear door opening then another about 40cm back from front door opening which are spot welded to inner sill and outer sill.
The spot welds you remove are on door flange lip, at door opening and along under sill. Do not drill inner welds, they hold floor in place and that is a structural join. Remove complete sill,inner and outer, car will basicly fold in half.

[Pagie84a]

http://www.toymods.org.au/forums/showthread.php?t=75344
have a look through here there are photos of replacing of the rear section of the sills

[Pattymac]

Okay maybe I'm misinterpreting what the inner sill is, is the swiss cheese part in the pic the inner sill? You can also see where I made the cut. Sorry for so many questions it's just if I eff this up I'm gunna be shedding manly tears

[TA22 GT]

Hi,
Grind a drill bit like below to remove spot welds.


Check my site for how I used this for spot welds on my cross member

https://www.facebook.com/pages/Class...537?ref=stream

Cheers,
Simon

[Pattymac]

I've got a spot weld bit for the time being but when it ends up going blunt I'll definitely give that a go.

There looks like there is a bunch of info I could use on the 1stgencelica forums but they aren't taking members from what I can see, such a bummer.

[Pattymac]

Are you sure the interior spotwelds aren't supposed to be unstitched to install the new sill? It looks like the new sill would slot in perfectly if I did that. To clarify I've got an entire new sill I'm chucking in, and have unstiched the spotwelds top and bottom along the door opening and below and those interior weld are the only thing holding it on from what I can see.

[Pagie84a]

your inner sill is toast too. Swap that out first and pump ur sills full of rust preventative