welding tr3a inner sill

[ekamm]

I posted on another thread on the triumph page and there wasn't a lot of activity on it.
I haven't the resources to do a full resto and am only sprucing her up and driving. On the whole I have very little rust on the car but yesterday as a part of new interior installation I pulled the kick panels off and surprise. Looks like I'm going to do some sheet metal work.

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Matching pairs, the driver side is a little worse but the floor is in fair shape and dealt with the scale on it some time ago.
I am looking at the punch and flange tool to make it easier,stronger and look better. If I make a flange instead of plug welding why not just make a complete bead down the repair( a little at a time and cooling of course)? my other question is after cleaning and then using a cutoff to remove the area to be replaced will I need to make a 90 at the floor to overlap. and if so on top of the existing floor or under? And one more, Sealer after welding and before paint?

 

[GregW]

I posted on another thread on the triumph page and there wasn't a lot of activity on it.

Hi Eric,
In the Triumph forum, you'll get the best advice that is particular to your car.

I am looking at the punch and flange tool to make it easier,stronger and look better.

I have one of those and wished I had bought one that made a larger hole. I think mine is 3/16". It works well for sheetmetal to sheetmetal plug welds, but welding sheetmetal to something thicker, I usually have to drill a bigger hole.

If I make a flange instead of plug welding why not just make a complete bead down the repair( a little at a time and cooling of course)?

I like plug welds better. They clean up much easier and you'll have a tough time grinding the edge without weakening the bond on a bead weld. This might not be an issue with what you want to do, but I also think a plug weld will have less of a tendency to "hinge".

my other question is after cleaning and then using a cutoff to remove the area to be replaced will I need to make a 90 at the floor to overlap. and if so on top of the existing floor or under?

A 90 along the floor would make the patch piece stronger, but not knowing much about Triumphs I'll pass on a recommendation for that.

 

[Britishautobody]

You might want to also question the integrity of your rocker panels,looks to have allot of surface rust inside from your pics. These areas seem to rust from the inside out. The outer rockers become very weak before the small pinholes start to show up, at least from my exp etc. These cars have a full frame so welding a patch I would say is more personal preference for approach. Butt weld a piece for a clean flat look. Harbor Freight sells the flange tool cheaply.
You can weld this any way you'd like, sounds like you have a handle on it.
Sealer before paint correct, some sealers you can paint after a hour, make sure to get a "paintable seam sealer".