Rear sill vs floor panel

[Splangy]

Wow. had I done my research properly i would have got that awl-teq sill. Mine is a piece of 2x3 steel, beefy enough but i had to weld the bolts in. There is no indent for the door catch either....

I ended up welding the floor over the sill since it made the most sense.



You can also see where i added 1/4 flat bar instead of the captive nuts for the spare carrier. worked out great. The sill cover is made of 16 gauge as well, so pretty solid.

Why the big weld booger along the seam instead of spot welds? If no spot welder, than why not drill holes and fill with a mig (then grind) to make "fake" spot welds? Then fill in the seam with seam sealer and it'll look clean.

 

[Ambrew]

No rattles on this truck. The floor was too short to spot weld as in other places, so a bit of grinding and she'll look just fine. This aint a show truck. those welds are actually 1/16 or so high. not that bad.

 

[belaw]

Does awl_TEQ have a website or electronic "store"? I'd like to see if me makes a sill for early (10/69) 40's and check his pricing.

Brian

post pictures of your build problems please, they will help us help you.

check out the following photos from a Mud buddy of mine awl_TEQ you will see that the late model sills that he sells leave a lip to lap weld over

 

[hedgehog23]

he is a vendor right here on mud. check out this thread for a better idea of what he makes, and pricing. just PM him with any questions and order requests.

https://forum.ih8mud.com/merchandise-storefront/373024-40-series-misc-metal-fabrication.html <----------- This is a link

 

[Awl_TEQ]

That would be my Marketing Manager, hedgehog23. Hard at work as usual.

 

[hedgehog23]

Us Canadians have to stick together eh

 

[belaw]

I agree. The original design is a mud catcher. Here's what I did--a 2.5 inch 3/16 walled tube with angle iron welded on the side for the floor to sit on:

Link: Senor Aguas: rear sill and rockers...

Senior Aquas:

I'm curious- did you put "horns" on the end of the replacement sill you built?

I know the extensions help provide support for the rear corners and the stock tire carrier, but they also seem to be guaranteed rust points.

I have a sill replacement in my future and since I don't have a stock tire carrier I'm thinking about omitting the "horns" and just running a straight length of 2x2 square tubing.

 

[Senor Aguas]

I have 3/16" thick bud built quarter panels. I welded the sill to the quarter panels in the area that would have had the horns. It doesn't extend into the rounded part of the quarters, but at 3/16" thick, it doesn't need to. I'm not sure what I would've done with stock sheet metal.

 

[DirtDauberGarage]

Here is a thread I just made with a "HOW TO" do it step by step. If any of you decide to tackle it yourself, I hope this helps.

"HOW TO" - Replace the Rear Sill on an FJ40 – STEP BY STEP

There are many threads about sill replacement here on MUD, but I could NOT find a comprehensive “step-by-step” guide on how to do it. Therefore, I decided to create one in hopes it might help someone in the future. It was my first time replacing a sill, and I took my time to ensure I did the...

forum.ih8mud.com