1955 Austin A30

One step forward two steps backwards. Started the day by waking up with a migraine. So took some painkillers and hid in a Dark room until it subsided. Then managed to muster up enough enthusiasm to venture into the garage.
Yesterday when I checked for panel fit, it was all looking good. Except For one area.



Something is not quite right towards the front bottom edge of door and sill.
With the door open it’s clear that the new sill is narrow in comparison to the original.



Some what annoying as it’s a £200 panel. But I can’t leave it as it is. So with an extra large dose of brave pills I sliced up my new panel.



Then it was a case of opening it up till it looks right, and weld in some extra metal and flattened off the welds.





And then offer it up and see how it looks now.
A lot better then it was, the bottom of the door matches the sill and the A post fits better as well.





And that’s all I managed to get done today. It did take a while to weld it up as I was trying not to distort the panel.

I've the exact same issue on my A35, can't decide if it's a wing issue or sill replacement problem. For the price of the panels you do wonder sometimes.

I had a look online today to see if anyone else had issues with the panels from the supplier. And found someone else who had the same problem.
Also mine needs the reinforcement for the jacking point cut down. As at the moment the bottom of the sill doesn’t line up properly with the bottom of the inner sill.

A Previous owner had started to remove the skin, had a change of plan and tacked the skin back on.... badly... I have spent a week welding ..grinding and a bit more welding and grinding, I almost have the door gaps about right, I may lead the edges to make the fit spot on..

Nothing worse then trying to undo someone’s else’s previous bad work.
I have to replace the bottom half of both my rear doors. Can’t say that I am looking forward to that job.
Do love what you are doing to your van. It will be pretty special when it’s done.

Another day of steady progress on the Austin. Today’s mission was to fill in the large gap between the wheel arch and the sill.
I had brought a repair panel which is a lot bigger than the area that needs replacing.
But you can’t get the small section that I need on its own.



So it was a case of carefully cutting off the bit that I needed, and trimming the bodywork to fit.
And surprise surprise the new panel didn’t fit. Just like the replacement sill it was going to require some surgery .
The shape is not right so I had to use my hammer & dolly to reshape it. But it still would not line up.
It seems that it was made too small, so I had to put a cut down the centre and tweak it a bit.



Then steadily zapping it with the welder and hammering it as I closed up the gap. It just needed a slither of metal in end bit.
And eventually we end up with this.



After that it was a case of carefully grinding the welds down.



All that is left to do now is put an end piece on the sill and grind all the welds down. Then the drivers side is all done.
Then I just have the fun job of trying to free the front brakes off. Then push it out side and turn it around and push it back in.
And repeating all that again on the passenger side.

Thanks,
I have probably made more progress in the last ten days than I have in the last ten years.
Back to work next week so progress will probably slow down a bit.

Don't stop now, you are on a roll.

Depends on the size pins you are using, I usually drill 3mm holes for the copper coloured ones