Is it possible to completely replace the sills/jacking points (86 360)

[pettaw]

As the guy who welded it for last years MOT did a complete hash job of welding some patches onto it. Bearing in mind I know nothing about welding, but am mechanical, and quick to learn. Some advice please. I need to use the car until probably next year and then I'm gonna try and restore it properly to original spec as a kind of project car.

Andy

Probably more difficult would be the cutting out of the old sills, bracing of the car to stop it bending while they`re off and tracking down the new panels.

You would probably be much better off attempting to do decent local repairs - with care you can make them almost un-noticable. and there is a fair chance that you could fabricate the repair panels yourself.

IIRC Haynes do a manual on body repair which covers a lot of the procedures you would use.

I don`t think that there is much mystery when it comes to basic welding - you need to set the machine up correctly, be conversant with relevant safety procedures and have a rough idea of how to produce welds properly - info that you could get from a book - and loads of practice. I`d suggest cutting up a sheet of steel and spend a weekend welding it into amusing shapes before attacking the car.

I`d suggest using a MIG welder - an arc welder can be a bit fierce for body panels in unpracticed hands. Practice until you can produce nice flat welds that go all the way through the metal, with an even heated band to either side. The main art, I think, is balancing trying to get well penetrated welds without blowing holes in the metal.

Will Plummer

[pettaw]

Thanks, Haynes seem to produce a book for almost anything :)

[foggyjames]

I keep meaning to learn how to weld, and that Haynes book sounds very interesting!

In the meantime, you could always try another garage? I think you've had bad luck with this one, as all the work we've had done has been top-quality. We use an independant Volvo specialist.

cheers

James

[vjck_uk]

Hi there,
The advice you have been given by Will is spot on.
The only thing I would add is you must make sure you cut back to good metal and clean all paint and any rust off the edges of the hole before welding.
I use a small angle grinder with linishing pads fitted as required and a rotary wire brush to finish before welding.
The more trouble you take in preperation the better the final result.
If you don't do this you will end up welding patches onto patches and end up with far more work and it will look a mess.
Mot standards require all patches to welded all the way around not bits here and there.
I us a mig welder and if you use good wire and don't skimp on the gas pressure it will come out great.
I have had plenty of practice as I had a Ford Sierra before the 240 and it was a rotbox,2 days of prepping and welding the last time.
A nice bit of underseal works wonders at the end and will cover any iffy bits.
If the patch will be visible while standing the underseal it and the paint it over with the car colour.
After my 2 days I was almost enjoying it as the more you do the better and easier it becomes.
Best of luck and put some tape around your sleeves as hot bits up the forearms are not reccomended.
Vaughan