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Outer Sill Alignment - Again with pilars

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LanceLyon

Jedi Hopeful
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I HAVE RE-POSTED THE PICTURES!! I need help with the alignment of the outer sill to other adjacent parts.

Please take a look at the attachments that are included. I have attached a quarter panel repair section to my new outer sill. When the repair panel is aligned with the outer sill and the quarter panel, the outer sill will not "seat" on the notch in the rear outrigger.

If I break the weld between the repair panel and outrigger and let the sill seat on the outrigger, then the repair panel does not line up properly with either the sill or the quarter panel.

Does the sill always seat in the ourigger notch? The rear outrigger is original (with a little repair). Both new outer sill and repair panel are "KAS" through Moss. Can I count on them to be "reasonably" correct as to shape. length, etc?

HELP! Any comments or advice from experience will be appreciated!

Lance
 

Attachments

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Re: Outer Sill Alignment

Sorry for the problem. I think they must have been lost as Basil switched the server over. The pictures should be viewable now.
 
Re: Outer Sill Alignment - NEW ATTACHMENTS

HI Lance , Yes the cill seats in the out rigger notch and Kilmartin repair panels are as accurate as you can get,but some fitting may be required.---Fww---Keoke /ubbthreads/images/graemlins/yesnod.gif
 
Re: Outer Sill Alignment - NEW ATTACHMENTS

Hi LL,
The arrow on the picture shows the most important line of the repair panel. That is the one that determines how the door shut pillar lines up with the door itself. Once the shut pillar is installed there are three things that mount in front of it. The lip of the rear fender, the aluminum door trim and the piece of piping that goes between those two pieces. You have to take the thickness of those pieces into account when setting your door gap. Don’t feel obligated to use the whole repair panel. It was designed to cover a range of rust repair problems. I notched mine where the blue line is so the rocker panel would sit flat against the sill.
133688-sill.jpg
 
Re: Outer Sill Alignment - NEW ATTACHMENTS

Thanks for the input on this issue. I can see the line that Greg is talking about. In a perfect world the new pilar would rest snug against that. I tacked the new pilar in place but now have an unacceptable gap. The attached picture looks at the latch threogh the gap. The silver seen is a scrap of the aluminum trim for spacing. BROWSER WON'T LET ME ATTACH THE PHOTO; TOO BIG.

Is it acceptable to slide the pillar forward to close the gap? To do so would then create a gap between the repair panel and the pilar. I suppose I could then close that gap with a strip of sheetmetal.

What do you think?
 
Re: Outer Sill Alignment - NEW ATTACHMENTS

Hi LL,
Email me the picture and I can resize it for you. I sent you a PM a while ago, there should be a blinking envelope in the upper left corner of the page.
I’m not sure how much of the inner fender you removed, but I think it would be better to reposition the repair panel than to add another piece of metal if possible. One of the problems lies in the fold on the leading edge of the repair panel. That will interfere with the placement of the triangular box that keeps the pillar at a right angle to the inner fender. Some, if not all of that would need to be ground off. Additionally, the more pieces you weld in, the more warpage you’ll have to deal with.
 
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