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Old 29th May 2019, 07:53 PM
MikkiJayne MikkiJayne is offline
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I had a similar crack welded up in Big Red by a local tig welding specialist. He commented that it was exceptionally hard aluminium and quite hard to weld, but it came out well.

Bear in mind that the sills on these are full of flammable expanding foam. For Big Red we had to remove a body grommet from inside the rear wheel well and fish all the foam out with a wire hook before welding. Worth checking that its not in, or next to, a void. The heat travels a long way in aluminium - Big Red's hole was about an inch diameter and I'd cleaned up 2 inches around it. The welding burned off another inch or so of paint so I ended up with a larger area than expected to refinish.
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