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Photos of my outer sill repair

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M

mightymidget

Jedi Knight
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Decide since my $500.00 Midget was half way ready for the road as a daily driver I would get back on the Wifes Bugeye

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I had already stripped the metal from the car last winter during the spring box repair. This photo shows the wire loom I have place to run between the sills. I got the wire loom from NAPA and figured out a maxium of 8 wires would fit in the openings alowed. So I placed 8 wires in the loom and then I wrapped loom with Blsck tape. I wanted as many wires as possible to the rear. Tailights, brake light,left/right signal,gas gauge,fuel pump. this leaves me with two extra wires should I need them
 


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I made alot of the pieces that supported the rear corner of outer sill. This area as in many Bugeyes was completly rusted out. so I just tried to make the panel so they will look like originals.

The green stuff you are seeing is dynoglass. after I grind the welds smooth a apply a light coat to fill in all the pitts and such. Plus dynoglass is water proof. I wil let it dry for day then come back sand down and apply light skim coat of bondo
 


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I still need to repair the lower rear wing extention. Just have a hard time buying the part ($189.00. I have tried to make it but has many curves to it. I will try again,

The outer sills and end extentions I got from Moss where excellent
 
mightymidget said:


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I still need to repair the lower rear wing extention. Just have a hard time buying the part ($189.00. I have tried to make it but has many curves to it. I will try again,

The outer sills and end extentions I got from Moss where excellent
Click to expand...

I made mine...it really wasn't as hard as I thought it would be. I traced the two curves(one for the wheel well arch and the other bottom curve under the panel)onto cardboard then transferred those onto a piece of 1/8" steel sheet. Then I cut and ground those curves into the sheet and used it as a "bucking block" to fold the new sheet metal up around. now you're left with a flat piece of sheet metal with the two curved flanges bent into it. next you just need to beat the compound curve into the panel with a shot bag and mallets. this photo shows the side I changed the wheel arch on also, so it does'nt show the fabricated curve on the wheel arch that I made on the other side. but you get the idea. I made the inner closeout panel the same way. this web site has some good photos of the technique I'm describing. https://www.cardomain.com/ride/2203663
 

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pretty impressive all!
 
looking good, fabricating your own panels is a real art in itself - nice work !
 
Boy now we know who the experts are. Well done.
 
I like the idea of putting that wire loom inside the sill, wish I had thought of that. It is tuff to put behind the inside covers if you add wires. Nice job.

Mark
 
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