Hello,
I tried 2 different approaches on different sides the best was to:-
Cut away the outer undersill
- outer-undersill-r-h-traveller-lmc-hadrian-uk-made-p828399-2492_thumb.jpg (6.06 KiB) Viewed 1133 times
Then the boxing panel and boxing panel extension
- boxing-panel-extension-r-h-traveller-with-hole-p828500-4133_thumb.jpg (3.31 KiB) Viewed 1133 times
- boxing-panel-r-h-2-door-trav-conv-lmc-hadrian-uk-made-p828492-2517_thumb.jpg (7.64 KiB) Viewed 1133 times
The boxing panel extension is hidden behind the woodwork and I had the woodwork off with my car
The boxing panel needs to be cut clear of the floor edge panels but i left the edge panels in the car until later. The boxing panel is a swine to get out but if you systematically clean up the surfaces, then drill away the spot welds it does come out eventually. The boxing panel is tricky to get out from behind the A Post and B post. You may find you need to replace the bottom of the A-Post and B post as this can uncover rust or bodged repairs.
then reverse the order and tack weld the boxing panel and extension to the old inner sill step, to the inner wing at the front and back and to the A & B Post. Getting everything lined up. I did lots of door test fits to make sure the panel gap is right.
- front-inner-wing-domed-full-section-r-h-p828414-1906_thumb.jpg (7.09 KiB) Viewed 1133 times
Once that's in and reasonably solid you can cut away the floor. I used a half-floor
- half-floor-r-h-high-back-section-without-inner-sill-step-lmc-hadrian-uk-made-p1237071-5524_thumb.jpg (4.23 KiB) Viewed 1133 times
but without the sill step which I fitted later.
cutting away the old floor to fit the new floor is a very difficult job and needs to be done very carefully to ensure a good fit. I butt weld panels which means the fit has to be extra good. The upright bit at the back of the repair panel from ESM I cut off as the rear seat box section was in good fettle. cutting this out also takes out the floor edge panel
Tack weld the new floor in
Next cut away the inner sill step and tack weld in the new one.
Once thats done you can consolidate the tack welds and get everything solid. I dont have a spot welder so I seam welded the boxing panel to the inner sill step
Next I turned the car on it's side and welded in new floor edge panels and then welded in the outer undersill.
It took me about 3 months of spare time to get that little lot done but as long as the doors still fit, the results not a bad-un
