Help needed on preparation on outer sill for welding

[A_Bright_Spark]

Here are more pictures of the outer sill that needs welding.

Nearside:

Offside:

It looks like a akward weld as it will need a plate under the jacking points. Not sure how to do this. Remove the jacking points?? It also looks like this has been patched before on the Offside :? so is this going to be a right can of worms in the winter?

Looks like its been patched on the front nearside at somepoint too:

Rob

Not sure how to get in there and get back to shiny metal?? Any tool suggestions or tips would be fantastic thanks

Rob

 

[brightspark]

i thought i double posted there in the wrong section

 

[Sean]

Blinkin heck!
that's pretty far gone for a t25

the previous repairs havn't done it any favours burning off the cavity wax - Ive scrapped worse editBETTER!

to even get close to doing a decent job i reckon the trailing arms need to come off and the bush housing "jacking point" needs to come off, its some pretty heavy duty welding too VW were built from solid stuff

 

[A_Bright_Spark]

Blinkin heck!
that's pretty far gone for a t25

the previous repairs havn't done it any favours burning off the cavity wax - Ive scrapped worse

to even get close to doing a decent job i reckon the trailing arms need to come off and the bush housing "jacking point" needs to come off, its some pretty heavy duty welding too VW were built from solid stuff

I should of explained that this is the reason my van has failed its MOT this year. We have not yet been on holiday and we are looking for a quick fix until I can sort it properly in the winter. The MOT tester and another forum suggested a patch over the holes and paint over until winter.

Can't think how to get in there and clean it up though??? All I can think of is sand blasting it....wish I had one though

 

[Sean]

Front, cut out a section of the outer sill, patch the inside of the jack point and weld the flap back on the sill. At the rear patch the holes and pray.

Id be cautious as the rear suspension mount is in a real bad way