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 How much welding time to replace a sill?
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andydeans3
V4 Guru

United Kingdom
1194 Posts

Posted - 03 Jan 2019 :  19:23:01 Show Profile Reply with Quote
Guys
I've discovered a little rot in my drivers side outer sill.
Rather than faffing around "patching", (given that Malbrad have complete galvanised outer sills available), I plan to replace the whole sill.

So I can get a handle on costs, can anyone give me some idea how many hours are required to cut out the old sill, and fit and weld a new outer sill in?

Andy

1978 LHD SAAB 96
1978 MGB Roadster
2008 LHD "Classic" Renault Twingo
1991 Nissan Figaro

melle
V4 Guru

United Kingdom
2831 Posts

Posted - 03 Jan 2019 :  20:33:39 Show Profile Visit melle's Homepage Reply with Quote
Fully depends on how much previous bodging has been done... Removing a pristine sill is a matter of drilling out (lots of) spot welds and making a few cuts with an angle grinder. However, usually others have been there before, which can massively complicate matters depending on the quality of their work. I've never replaced a complete sill, patched a few though.

www.saabv4.com
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andydeans3
V4 Guru

United Kingdom
1194 Posts

Posted - 03 Jan 2019 :  22:04:44 Show Profile Reply with Quote
Melle

Aye, there has been some patching been going on before, which is why I'd like to cut it all out and put in a new sill, rather than continue the "bodging".

Andy

1978 LHD SAAB 96
1978 MGB Roadster
2008 LHD "Classic" Renault Twingo
1991 Nissan Figaro
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Dirtbiker
V4 Mad

United Kingdom
721 Posts

Posted - 04 Jan 2019 :  09:49:16 Show Profile Visit Dirtbiker's Homepage Reply with Quote
Hi Andy,
Have a look here:

http://www.saab-v4.co.uk/speedball/topic.asp?topic_id=2683&whichpage=3

I used the panels from Malbrad which were very good. Bear in mind you only get the lower sill. My only criticism is that they were galvanised which seems pointless to me as you have to grind it back to weld anyway.
Difficult to estimate time because as Melle says you dont know what youll find once chopping starts. Took me ages but Im not a pro. Reckon I could maybe do one in a weekend if I had the house to myself and no distractions but if the floor needed work then much longer.
Hope this helps,
Cheers
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andydeans3
V4 Guru

United Kingdom
1194 Posts

Posted - 04 Jan 2019 :  10:44:37 Show Profile Reply with Quote
Gareth.
Great thread.
What a project! Damn, I wish I could weld, maybe it's time to learn.

I can see that I commented on it, when tachometers were being discussed.

Perhaps I'll just get a patch done, but a properly fitted, "let in" patch, not just a plate stuck over the hole and welded.
I will ruminate about this over the weekend. I know a SAAB 96 guru locally, I'll go and see what he thinks.

Update Friday afternoon 4th Jan. Sills just arrived. VERY NICE....!!

Andy

1978 LHD SAAB 96
1978 MGB Roadster
2008 LHD "Classic" Renault Twingo
1991 Nissan Figaro

Edited by - andydeans3 on 05 Jan 2019 13:22:08
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melle
V4 Guru

United Kingdom
2831 Posts

Posted - 07 Jan 2019 :  21:22:36 Show Profile Visit melle's Homepage Reply with Quote
Buy that welder and get stuck in Andy! Certainly cheaper than letting someone else fix it and welding is very satisfying work.

www.saabv4.com
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Dynorog
V4 Fan

United Kingdom
134 Posts

Posted - 08 Jan 2019 :  06:34:24 Show Profile Reply with Quote
Deleted posted on wrong thread

Edited by - Dynorog on 08 Jan 2019 06:37:41
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Doive
V4 Fan

United Kingdom
123 Posts

Posted - 17 Jan 2019 :  11:44:43 Show Profile Reply with Quote
Andy, you're welcome to borrow our welder if you want to have a play yourself. Clarke 161TE, very easy to learn with.

Alternatively, take it down to the guys at Dirty Hands in Kirkcaldy, they work on all sorts of classics, and I know Kim there is a huge V4 fan.

1970 95 V4 van
1972 Sonett 3
1973 95 V4 estate
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andydeans3
V4 Guru

United Kingdom
1194 Posts

Posted - 17 Jan 2019 :  17:25:52 Show Profile Reply with Quote
Doive

Thanks for the offer mate.
I'm taking the car to Dave Lewis in Cupar, he's a SAAB man.
It's all arranged for 4th February.

He has several SAABs, including a couple of 95 project cars.
He's done work for me before. Great thing is he doesn't mind you getting your cuvvies on and getting stuck in with him.
Always good to know local welding shops though.
Where is "Dirty Hands" exactly in Kirkcaldy?

Andy

1978 LHD SAAB 96
1978 MGB Roadster
2008 LHD "Classic" Renault Twingo
1991 Nissan Figaro
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rannsachair
V4 Beginner

United Kingdom
92 Posts

Posted - 17 Jan 2019 :  18:47:21 Show Profile Reply with Quote
quote:
Originally posted by andydeans3
Doive

Thanks for the offer mate.
I'm taking the car to Dave Lewis in Cupar, he's a SAAB man.
It's all arranged for 4th February.

He has several SAABs, including a couple of 95 project cars.
He's done work for me before. Great thing is he doesn't mind you getting your cuvvies on and getting stuck in with him.
Always good to know local welding shops though.
Where is "Dirty Hands" exactly in Kirkcaldy?

Andy

1978 LHD SAAB 96
1978 MGB Roadster
2008 LHD "Classic" Renault Twingo
1991 Nissan Figaro

Dave Lewis is a name from my past, met him through Sandy Milton who I worked with and got me into Saab's, though I started in an 84 900 16v turbo s. He was into Saab's when I met him, probably in the late 1980's.
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melle
V4 Guru

United Kingdom
2831 Posts

Posted - 23 Jan 2019 :  21:36:47 Show Profile Visit melle's Homepage Reply with Quote
Andy, I was looking for something in my Flickr account and I happened upon this. ( (c) John Saab)



www.saabv4.com
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andydeans3
V4 Guru

United Kingdom
1194 Posts

Posted - 25 Jan 2019 :  21:31:17 Show Profile Reply with Quote
I know Melle, I'm worried, very worried!!

1978 LHD SAAB 96
1978 MGB Roadster
2008 LHD "Classic" Renault Twingo
1991 Nissan Figaro
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andydeans3
V4 Guru

United Kingdom
1194 Posts

Posted - 25 Jan 2019 :  21:40:17 Show Profile Reply with Quote
Tom

I'll ask Dave if he remembers you.

Andy

1978 LHD SAAB 96
1978 MGB Roadster
2008 LHD "Classic" Renault Twingo
1991 Nissan Figaro

Edited by - andydeans3 on 26 Jan 2019 14:51:05
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rannsachair
V4 Beginner

United Kingdom
92 Posts

Posted - 25 Jan 2019 :  22:28:59 Show Profile Reply with Quote
quote:
Originally posted by andydeans3
Tom

I'll ask Dave if he remembers you.

Andy

1978 LHD SAAB 96
1978 MGB Roadster
2008 LHD "Classic" Renault Twingo
1991 Nissan Figaro


Thanks Andy, he may recall I was into old motorbikes...still am

Saab engine in background, and bumper hanging up...amongst the bikes! welding on my saab at a bit of a go slow unfortunately.
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andydeans3
V4 Guru

United Kingdom
1194 Posts

Posted - 09 Mar 2019 :  10:21:24 Show Profile Reply with Quote
I won't be refitting the jacking points.

Made myself a "jacking block" out of wood. I chiseled a recess in the bottom, for the jack to fit into.
Works a treat.
Lower down is a photo that shows the crusty layers of corrosion around the old jacking point. This being a photo of the old sill when it came off.





1978 LHD SAAB 96
1978 MGB Roadster
2008 LHD "Classic" Renault Twingo
1991 Nissan Figaro
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