Looking for some advice on how to do the outer sills on me Mini i have linked immages below


Link


Cheers


Kev

drill through and spot weld. if you place a piec of alluminium underneat it makes for a neater weld. I would advise that in future you use a hole punch and punch the holes prior to welding. I always find welding from above is the best and neatest method

Drill or punch some 8mm holes in the lip and mig weld through them to the sill. You could do top and bottom of the sill with the same method or tack the underneath as long as it's tight to the floor. If you want to spot weld with an actual spot welder the lip you are welding to will have to be absolutely clean and good metal.

30 odd years since I did one but ISTR the main problem was keeping the outside seam thin enough to retain the plastic chrome trim on, in the old days you could get different depths of sill to cater for cars with rotted floors.
You end up using a combination of welding techniques, With seam welding MOT test now demands proper seam welding where a panel is spiced on to an existing panel however don't make the seams welds completely continuous allow small gap between runs.
You can get special MIG nozzles for puddle spot welding but I have never tried them.

Carefully plan the welds and clamping to minimise distortion.

I always replace the door step section, the inner sill and the outer sill at the same time using a proper spot welder where I can get it in and puddle weld the rest. It helps if you punch a hole and use a higher setting on the MIG when spot welding, make sure the panels are clamped tightly together

Bit of an up date

I got one of these




And been busy today