n/s sill repair

The front of the n/s sill was in poor condition. It appeared OK from first glance but it was rotted through and also patched with what appeared to be fibreglass at some point. It also had a patch welded on at the previous MOT:













The top of the sill where the wing bolts to was rusted but after a good rub down to clean metal, this area was rust treated.

All the completely flakey metal was removed to leave just solid metal. This was then rust treated to remove further rust so I had shiney metal to weld to:





As with the driver's inner wing there were some holes into the interior that needed to be patched once took back to good metal. This was done, and then the sill repair panels were welded in place. This took the form of two parts. One up to the jack point hole, and one to finish the remainder of the sill:



The end piece was then welded in, after a good coating of waxoil and rust remedy was sprayed into the sill. Then the whole repair was POR-15'd and coated in resin.



To get the repair nice and smooth some metal-based filler was used, then primed and POR-15'd again:



Then a good coating of waxoil all over the inner wing, including the end of the sill, and stone chip guard sprayed all along the sill:









Drain points were added at either end of the sill and the hole that should allow drainage into the sill was sealed as we dont want to invite water into the sills if we can avoid it!! The original design was to have a channel for water that went through this hole and out a hole at the bottom of the sill, but this just helps rust. The two holes at either end of the sill should allow water to escape if it does get in. The sill was waxoiled via the access holes that are inside the car (under the carpet trim) and along the bottom of the sills.

Some minor repair was also needed to the edge of the floor here. A flat metal piece was welded in here and sealed up, before covering in POR-15 and eventually underseal.