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Hi Guys & Gals

Just wanted to make a post on here to let people see how bad the rust with the sills can be. 

I have 2 at the moment that I will be welding up, so 4 sills in total I have just cut up one at the moment and have some pictures to show. 

Im not much of a welder so using a good old cheap flux core mig welder that should do the job 😄

I have some pictures of what its like and what my plans are, the area's are a bit tight to get the grinder into to grind away the rust … so just going to cut it all away! 

Let me know what you guys think, if you have any photos of your rusty sills/boot etc

Have the cold but should be doing this within the week or so 😄 Looking forward to it !!

 

So plan is to cut out all the rust, replace it with new metal, primer it where I cant reach after welding, plug weld ovr existing good metal then seam along the sill etc, also though  I might as well do the rear arch while I am there.

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Hi Scott. It looks like you have quite a bit of fabricating to do there. Once the tin worm gets started it is difficult to stop the only way is to cut it out. Good luck with your en devours ,and let us see pics on how things progress.

John. 

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Hi Guys 

So … Kinda all done, need quite a bit of filler but I think it will look alright :s

I did make a few mistakes hopefully that I can coverup. The biggest was I was trying to grind the welds away and well I ended up grinding away good metal so thin that it just cracked (right under the door) so had to cut that away so I could replace it with more metal 😕

In full tho… really good fun, just rather difficult to get into at some points and stuff. 

Ill post some of the during then make another reply for the after .

 

So as my pictures above, Ive created a panel to cover the (think its called a Gullet ? the big O cut out's) holes and welded them up. these weren't the finished product welded a lot more, made sure there were no holes but didn't grind them down as its on the inside.

 

underneath, I cut away some of the pinch weld so started to form what I had taken away. along with the bit on the right which was for the plate in the wheel arch to plug weld to. 

4th picture down you can see that box section trying to continue it all the way along. (I like this bit, feel that I done Good there) You can also see my mistake. on this photo and the other 2. So I had put these plates in thinking about how I would do the outer sill and thought id grind it down to see how it looked etc.... and ended up screwing it up as you can see the bit of good metal just at the bottom of the door sill bit 😞 wasn't happy at myself ! lol

 

Overall the inside was a mess … not so much anymore 😄

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So As you can see most of this was done in the dark with a few lights. I had planed on doing it thought the day but my pal needed help with his exhaust. 

So next day I managed to get the bellow done, not too happy with the outer sill, really happy with the join with the wheel arch but not so sure about the curvature of it … What's your thoughts guys ? I will be using some body filler and then seeing how it is after that 😛 I have another 2 to do as my other car neds it quite badly.

If everyone wants I can post about this here too ?

Here we have the finishing product ! 😄

 

Still need to plug weld the Sill bit, Forgot to do this at the time but I can easy enough go round with my drill and fill it in with weld. Cut the Pinch to the same level. 

Im quite happy with how it turned out, kinda. Where the new Sill meats the old sill im going to need quite a bit of filler for that 😞 messed that bit up.  Where the rear arch comes back, not sure if this is the correct curvature or if it matters, WHATS YOUR GUYS THOUGHTS ? also  need to bend it back so its not a sharp edge. 

 

 

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So, its getting there Slowly and my god body filler stinks and is hard to work with … Done plenty of filling walls plastering ceilings walls etc but body filler … different kettle of fish 😂

 

Still need to give it another layer and then a fine sand with 180 then a wee coat of paint … nothing special just black maybe, just to see how it is. 

So for the first time doing welding and some body work etc … What do you guys think ? Im a little :s about the rear arch bit besides that im really happy with it so far ...

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you've done a good job, I have just rescued a 2004 sport with rotten sills, it appears they rust because when they inject waxoyl or what ever they use it never gets to the rear part of the sill so they eventually rust from inside , first sign is bubbles on the sill trying to get through the stoneguard….  

 

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2 hours ago, whiteman said:

you've done a good job, I have just rescued a 2004 sport with rotten sills, it appears they rust because when they inject waxoyl or what ever they use it never gets to the rear part of the sill so they eventually rust from inside , first sign is bubbles on the sill trying to get through the stoneguard….  

 

Thanks Whiteman

Yeah I have a black one that im doing next, that has … well it has been bubbling for about a year or two 😕 so not looking forward to whats behind it. 

Any pictures of before during and after your repair ?

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You can see that after the stoneguard was removed the small holes can be seen then tapped with a hammer it is very thin as its rusting from the inside, when looking inside you can see where the waxoyl or whatever they use for protection stops so therefore rust appears, it was cut out and treated with waxoyl then covered with new metal and finished off ready to spray.. You can catch it early and no need to do as much as you have done but I have not seen one of the old is200s without the dreaded rust....its the stoneguard which hides it for many years until its too late when you see the bubbles appearing ...

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