The middle sill has by far been the biggest pain in the arse on the van thus far as so little of the original was left so I’ve had to make new sections and trial fit it to the van countless times (I’m still not sure if the door will fit correctly, I’ll only know once I’ve got it tacked in place – hoping my measurements I took before I removed it are ok!).
I made up some sections to extend what remained of the old sill:
And ground flat. I had to fillet weld some parts of the repair to the top section of the sill, the finger sander was perfect for getting this flat as any protruding welds will stop the roller from rolling.
And here it is trial fitted before I can weld it in (I’m going to paint the inside of the inner sill and the back of the middle sill before I do any of the welding).
The distance between the top and bottom track, and the back of the track and the front of the threshold are as close to the original measurements I took before I took the sill out as I’m going to get. Once I get it tacked in place I’ll be able to trial fit the door and pray that it fits (anything is better than what I previously had as the front never quite matched up, and the rear of the track had collapsed meaning we could never open it fully).
Hopefully I’m not far off finishing the sill as I’m sick of the sight of it now.
