TR6 TR6 outer sill replacement

[hondo402000]

after removing the front fenders I have some holes in the outer sills, I have not removed the paint below the doors but one would assume there to be some holes there too. So what is the difficulty level of removing the outer sills and welding new ones in? I did a search but could not come up with any threads. I was not worried too much about the ones behing the finders but under the doors maybe, however since I plan on rolling on the truck bed liner material after the paint job, I could just POR the outside and put a layer of fiberglass to cover the holes and then truck bet liner

Hondo

 

[tdskip]

Hi Hondo - the outer sills aren't too terribly bad to replace, but it does require a fair amount of time to remove them properly and then refit. Maybe TR6oldtimer and some of the other folks here that have done it can share their experiences.

Depending upon how large the rust holes are you might be able to leave the larger sill in place and just do localized welding - the sills tend to rot at the bottoms not the top unless they've gotten pretty bad.

I've heard that finish paint over POR15 can be tricky.

 

[Gliderman8]

I replaced the drivers side outer sill on my TR6. Although tedious, it is not the worst thing to do. I bought a spot weld cutter and carefully drilled out the spot welds. Then I used a reciprocating saw to cut away the outer sill but left the inner sill intact. The photo below show the body turned completly over laying on its back with the drivers floor and outer sill removed.
I took the opportunity to replaced the drivers floor pan at the same time.