Another Rusty Hole

[R1cho]

Well today i spotted a rust bubble on my sill so thought i would scratch it off and treat it with some of that rust stuff but instead of scratching the paint off my finger went straight through so now need to get it welded for mot, but today i was wondering if there is a way of uprating the sills? so this wont happen again, any ideas or has anyone replaced their sills with indistructable ones?

 

[zippy656]

ive got two holes.. one each side...

so very intrested too

 

[clivvy]

which end of the sill, rear? very common rust place. i dont think there is anything special you can do other than having new metal welded, or perhaps removing the sill all together and replacing! Id just have the rusty bits cut off, treat the inner sill, have the outer sill welded on, treat that then paint then perhaps fill the sill with waxoyl!:augie

 

[R1cho]

yes it is at the back near the wheel arch what about using something like this to build new ones? would that work?

 

[solarman216]

weld plate over the dodgey bits, drill holes, that you have purchased rubber bungs to fit , into the top of the cill/step and spray loads wax oil inside, Rick

 

[clivvy]

I believe that will be fine, so long as you can form it correctly. The rear sill, as you have seen, is tapered, and not flat, so for it to look right you will need to hammer it to shape and grind it down perhaps, but then im no expert!

I suppose another option is to have it welded on, then use filler to create the shape!:thumb2

 

[jims-terrano]

got to say if I could weld and had my own kit I would probably remove and fabricate complete new sills inner and outer and then treat the buggers so it doesn't happen again. I guess the thicker the better metal but I guess it could get a little over kill. Also keep an eye on the rear seat belt mounts inside the rear wheel arches.

Jim

 

[R1cho]

wonder if these would be better, could rust treat them then put ali chequered plate of the top would be able to shap ali easy into a taper at the end

 

[clivvy]

they would suit the inner sill, but you may well find the inner sill, which is structural, perfectly fine. Most people just fill the gap between inner/outer with waxoyl-no more problems!

I believe fiesta sills are suitable too, cant remember which MK though...

 

[R1cho]

they would suit the inner sill, but you may well find the inner sill, which is structural, perfectly fine.

yea but if i did that i would have a unique t2 lol

 

[solarman216]

yes it is at the back near the wheel arch what about using something like this to build new ones? would that work?

Bally hell that stuff is far too heavy, and it is galvanized, no god for welding unless you wish to gas yourself, I think arsenic is produced but could be wrong, no all you need is the same thickness plate for free as off cuts from your local sheet metal guy, usually they will let you rumage in their skip, no good painting the inside before you weld the weld heat just kills the paint, inject waxoil after, Rick

 

[R1cho]

I think arsenic is produced but could be wrong,

i'll keep away from that then lol

 

[larson]

im plating mine up with stainless as i have off cuts...well thats the plan

 

[spudd]

i noticed a couple of tiny rust spots on my 02.so sunday i covered the sills with paint stripper after an hour scraped off.once down to bare metal the amount of surface rust was scary. i treated with jenolite, 2 coats of hammerite red oxyide.will give coat of black hammerite then spray on gravi guard overpaint to match the car and fill with waxoyl.the 96 terrano sills are unmarkedand like new.

 

[R1cho]

the 96 terrano sills are unmarkedand like new.

thats right rub it in lol

 

[solarman216]

im plating mine up with stainless as i have off cuts...well thats the plan

Nice idea but stainless is nothing like as easy to work as mild steel and it does not welt to steel as easy either, you using stick or mig, if mig I think you need a different gas mix, I have only welded ss to steel with stick but that was 4 mm thick stuff so no prob, a mate of mine is a professional ss welder (makes hospital equipment) I could find out from him what mix to use, Rick

 

[larson]

i am a welder and you can weld ss to mild on a mig piece of piss...with normal wire



there wont be a problem welding but forming will be harder but i also got a lazer cuter and press brake/folder at work to help me:lol

 

[zippy656]

care to do a traviling workshop..

cant pay, but free tea

 

[larson]

nice idea if esso start giving diesel away

 

[R1cho]

i'll bring the biscuits lol