Sills Cross Section Diagram.

[Welsh_Stag]

Afternoon All.

Are there any good cross section pictures of how the sills, Floor panels and Outriggers etc come together when welding please?

Here's an example picture of what I'm looking for from an MG Forum.

Many Thanks.

[PJ W Yorks]

Good question

[dasadrew]

Tony Hart (Stag Specialist) sells a CD with fantastic photos of all of the body construction and the individual sections before they are put together. There is a warning that the images are all copyrighted so I'll not post them here. If you have time, I could try and do a diagram based on what the photos tell me. AFK in a couple of hours for a weekend break so won't be until next week.

[Philip Wardle]

I don't have a cross section picture, but I did find Richard's YouTube on sill repair very useful .. https://youtu.be/ayuMHST8qFk

[mole42]

One point to note is that early cars had a much stronger sill structure than later cars, with two strengthener webs inside the outer panels. It was similar to the big saloon cars, but with an extra panel, presumably to try and avoid body flex, which the T-bar did all on its own.

[jbuckl]

sill.png
apologies for shoddy sketch... rushed.

[ramjam2005]

sill.png
apologies for shoddy sketch... rushed.

Expanding on jbuckl's diagram, On my 1972 Mk 1 (without the middle strengthening 3rd sill panel) I thought the Inner sill INTERNAL face projects a little further inwards by at least 1/2" - 3/4" approx ( 12mm - 18mm in new money) creating a bottom lip under which the floor panel sits (extending outwards). The outriggers then sit under the floor panel butted up to the chassis rail at its inner end and butts up against the lip of the floor panel at its outer end.

So a cross section from the outside working inwards, the order would be: 1 - Outer Sill edge, 2 - Inner Sill edge, 3 - Floor panel return edge, 4 - Outrigger lip.
If you have the middle strengthening sill it sits between No.1 and No.2

Someone more knowledgeable will come along I'm sure and either agree or correct me ?

[jbuckl]

Expanding on jbuckl's diagram, On my 1972 Mk 1 (without the middle strengthening 3rd sill panel) I thought the Inner sill INTERNAL face projects a little further inwards by at least 1/2" - 3/4" approx ( 12mm - 18mm in new money) creating a bottom lip under which the floor panel sits (extending outwards). The outriggers then sit under the floor panel butted up to the chassis rail at its inner end and butts up against the lip of the floor panel at its outer end.

So a cross section from the outside working inwards, the order would be: 1 - Outer Sill edge, 2 - Inner Sill edge, 3 - Floor panel return edge, 4 - Outrigger lip.
If you have the middle strengthening sill it sits between No.1 and No.2

Someone more knowledgeable will come along I'm sure and either agree or correct me ?

Iirc less than 200 cars had king sill panels.

[new to this]

Expanding on jbuckl's diagram, On my 1972 Mk 1 (without the middle strengthening 3rd sill panel) I thought the Inner sill INTERNAL face projects a little further inwards by at least 1/2" - 3/4" approx ( 12mm - 18mm in new money) creating a bottom lip under which the floor panel sits (extending outwards). The outriggers then sit under the floor panel butted up to the chassis rail at its inner end and butts up against the lip of the floor panel at its outer end.

So a cross section from the outside working inwards, the order would be: 1 - Outer Sill edge, 2 - Inner Sill edge, 3 - Floor panel return edge, 4 - Outrigger lip.
If you have the middle strengthening sill it sits between No.1 and No.2

Someone more knowledgeable will come along I'm sure and either agree or correct me ?

The floor welds to the inner sill on the bottom lip as drawn but also under the bottom edge on the inner sill, cant remember if its the front floor pan or the rear The jacking points weld to the outer sill

Dave

[ramjam2005]

I read, studied and re-read the reconstruction as covered in the publication "Triumph Stag Restoration - Practical Classics & Car Restorers" before tackling the task. It's a compilation of their monthly articles all in one soft back special edition.
There were some past threads covering the same topic, even one where I described the method I adopted, but can't locate at present.

And a slightly tweaked version of jbuckl's cross section drawing reflecting my reply earlier. When reconstructing during a restoration it can be difficult to achieve this exact order of multi-layering if doing localised sectional repairs to the floor or outrigger ends.

Screen Shot 2023-08-10 at 21.50.11.png IMG_4132.jpg

Ray

[ramjam2005]

Eventually found the previous thread on this topic

[richardthestag]

I don't have a cross section picture, but I did find Richard's YouTube on sill repair very useful .. https://youtu.be/ayuMHST8qFk

Thank you, alas on Julian's (RIP sir) stag it had been greatly adapted and modified with MOT patches and lengths of angle iron over the years. The exercise in that video was to get it back together so that he could get back to driving it around. Mission achieved

I do have a copy of Tony Harts CD of the Body build. It is incredibly useful. Alas he no longer appears to be selling anything through his ebay. I wonder if he might consider allowing the images to be sold via the club or another appropriate agent.

Ray's diagram above matches what I have seen.

[new to this]

Eventually found the previous thread on this topic

I wouldnt go to the trouble of replacing the inner sill, its a load of extra work, ( its bad enough getting the outer sill off the car,the inner sill is much harder ) its normally the bottom 3-4 inches that rust and the front end , just make repair sections to repair what has rusted, use 1.5mm steel for the repair sections on the inner sill

this was a while ago now i bought my inner sill from the brothers, it was the wrong shape had to send it back the replacement was better, i bought an inner wheel arch for my Sprint that was really bad fit nothing lined up

Dave

[Goldstar]

I have a pair of stanpart inner sills in my shed.

[jbuckl]

I have a pair of stanpart inner sills in my shed.

Nice items…. But Sooner do a full heater rebuild than complete stag inner sills… that’s really deep!

mine needed 3 or 4 inches of new metal putting in & repairs to the jacking point straps.