Sill Rust - Replacement Or Fix?

[davemar 16]

My car failed its MOT today and one of the things was corrosion around the rear right jacking point. After a bit of poking and a quick go with the wire wheel on the grinder it turns out the rear few inches of the sill was complete rust. I've cut out the offending rusted part, which is a good 15cm of the sill from the back, and some of the structure behind it including the thicker bit for the jacking point.

 

I've now got to decide what to do next. Could I fabricate some metal to replace the parts I've cut out, or do I replace the whole sill? While I have got a welder, I'm very out of practice and don't want to do more than necessary. How easy is it to remove the whole sill cleanly so a new one can be refitted?

 

Do mobile bodywork welders exist, who can come out and do such jobs?

 

Edited April 16, 2014 by davemar

[Miles 331 1 Cars]

Just replace whats needed, Allot of problems come from welded up car's in the gap in the middle or behind a panel as you cannot get to the back of it to protect it so rust will come back in no time at all

 

Mobile welder's, Not many around these days as it's expensive to run, Next door to me is and he has a 7.5 ton truck to haul his stuff around

[davemar 16]

The proximity to the petrol tank does concern me for doing the welding too!

[dobboy 231 2 Cars]

is there a weep hole supposed to be in that area?

 

It might be worthwhile you taking the rear card out and having a look inside the bottom of the back wing.

[dobboy 231 2 Cars]

http://forum.205gtidrivers.com/index.php?showtopic=98052&hl=%2Bweep+%2Bhole&do=findComment&comment=878823

[harryskid 193]

The proximity to the petrol tank does concern me for doing the welding too!

Take it out and check for rot there too!

[m@ttc 30]

How easy is it to remove the whole sill cleanly so a new one can be refitted?

 

a nightmare! many, many, spot welds, then the inner sills will have rot too more than likely. as said just repair whats needed.

[Daviewonder 533 3 Cars]

How does the bottom of the quarter panel fix onto the car? Anyone have a cross section view?

 

I have a feeling I'm gonna be in this situation within the next couple of years.

[m@ttc 30]

spot welds, the last place to remove it from the car, the rear quarter bends down to allow access to them.

[davemar 16]

is there a weep hole supposed to be in that area?

 

It might be worthwhile you taking the rear card out and having a look inside the bottom of the back wing.

 

I've had a look behind the interior trim and the metal looks pretty clear in there.

 

I'm trying to work out whether the jacking point is just a thicker piece of metal sandwiched between the inner and outer sill or there's something more to it. It was so corroded it is difficult to tell how it was originally put together.

[m@ttc 30]

yes the jacking point is a thicker piece of metal sandwiched between the two inner and outer panels

im pretty sure these a water drain suposed to be near the b pillar, but is often covered with seam sealant by lazy factory fitting.

Edited April 19, 2014 by m@ttc

[john-melbourne 6]

Did you ever get round to fixing this?