Moss Motors, Ltd

I've done the hard yards on my 67 B and taken off the LHS outer sill and inner sill (items 31 and 32) and all the rust I have is the front two feet of the castle rail - it's still fairly solid but has a few holes.  The floors were replaced some time ago and are well and truly welded to the castle rail so separating the two will be a task.  My question is this do I need to replace the whole castle rail or will its integrity/strength be retained if only the front part is replaced? (I won't be doing the welding myself) (If it wasn't for the way the floor has been welded to the castle rail then I would replace the lot although separating the outer edge of the chassis rail from the castle rail at the jacking point also looks a task)

Hi Baz,

 I've rebuilt a few MGBs and whilst in theory there is no need to replace the old metal that is still good, having got down the castle sections I can see no real benefit in not doing so. Remember that in 3 or 4 years time you will kick yourself if you need to do further work because the dreaded rot is reappearing!

For my money, by far the worst part of the job is replacing the outer sill and re-integrating it with the rear wing (which you are already comitted to) so do the whole job properly. To separate the castle from the floor pan, either hire a nice large still saw / angle grinder and gring away everything that is not actual floor pan, or even go the whole hog and replace the floors too.

Hope this helps, even if it is not the answer you were hoping for!

Baz,

Your profile would indicate that you reside in California, yet your references to part illustrations do not match any catalog I posess. Nor have I, in all my years of doing this, encountered the term "castle rail". Help me help.

I will say that in general, taking a larger approach than just where's the rusty part? Let's just piece that in pays great dividends in structural integrity and in dimensional accuracy. The number and direction of welds needs to be considered more than simply trying to reduce the total square inches of metal replaced.

Really, where are you?

Cheers, Bill

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Motorbill
From Lola to Land Rover, If it's British and has wheels, it's likely I've bloodied me knuckles thereupon

Hi Rob.  Thanx for your advice but if you could indulge me further.  There was a bit of rot in the rear of the outer sill (under the dogleg) and the very front of the outer sill had had a piece welded over it from a previous repair that I don't even remember having done!.  Of course I had to take the whole sill off to see what rust extent there was - the inner sill  had no rust.  In fact the inner sill and the side rail are like new as is the castle rail other than the first 44cm (about halfway from the front to the chassis x-member).  As I noted the floor pan (which is also in near new condition) has been perhaps overwelded to the castle rail/side member.  Whilst I agree that it would seem logical to replace the whole unit I'm in a quandry about whether to disturb such a solid base by putting in a full rail or would the strength/rigidity/intergrity of the whole section be compromised by doing a bit of cut and weld on the front 25% of the castle rail? If it helps in your answer I am doing a nut and bolt restoration with a view to a "fast road" version.  While I'm at it, I managed to remove the outer sill flange from under the dash side panel (item 26 p236 of my Moss catalogue) but I can't seem to be able to do the same for the inner sill panel.  I'm in Australia and my car was sent our CKD and possibly this panel was welded/attached differently to where you are but any clues how to remove this would be apreciated as would how to get the small part of the outer sill off from under the A post without wrecking the A post flanges.

Hi Bill

Thanx your reply too.  You're close but no cigar for California - I'm on the other side of the Pacific in Queensland, Australia.  The English language still has a number of nuances - a castle rail is what Moss USA refers to as a "panel" (item 12 on their restoration parts diagram) the inner sill (item 32)  equates to item 11 and the outer sill (item31) is your rocker panel (item10)!

Hi there Rob (or any others).  I noticed on the Brown and Gammons website (and also the Hadriancarpanels website) a castle rail repair section (24inches) but Moss don't show such a panel. Are they not recommended? thanx any advice. cheers