Sills

[jims-terrano]

Right got to sort the sills on my project truck, have been giving it some TLC lately and it’s responding nicely and drives great.
So had a prod around the outer sills and sure enough they’ve holed. This is about the only area I have not touched since I bought it. Took it for MOT back in January and it failed on the sills, numpty garage patched on top of patches and passed it though I’m really not too sure how it passed the MOT as the area that’s holed hasn’t just happened.
So need to get the 3 litre clutch pedal bracket fitted, hopefully at the weekend and get that changing gear smoothly again before I pull my project truck off the road again. Wifes got my Skoda so she’s fine for getting to work so I’ll be fine swapping Terranos around.
So the sills, I got photos the other week which is helping my planning.

I’ve seen some sills on eBay from a company in Poland at 49.99 with free postage. Only problem is I really don’t need all the full depth of those sills but they are formed into a nice curved profile. Plus I did try contacting the seller to ask what thickness the metal is but didn’t get a reply which I’m not comfortable about.
Next option is to find a metal fabricator who can bend a profile into some metal of my choice. No idea where to start locally.
My other option is to buy the metal myself and bend a profile into myself. This I think maybe the way to go.
Not too sure what thickness to go for as I would like these to be long lived.

Should I just replace half of the sill or full length between the wheel arches?

What’s people’s thoughts and experiences with sills.

Cheers

 

[solarman216]

Having now completed the OS on my Troll, my thinking would be purchase some 2 or 3 mm thick plate the correct width, cut the old sill off and weld in the new metal, it is a sill after all not full gloss area that is part of the motors looks and at 2 or 3 mm thick will out last the car and more than that it is a cheap fix, Rick

 

[Banshee]

Jim I'm in the same situation mate with my Maverick.

I'll be watching this closely so I can do the same to that :naughty

I hope it will be me copying your excellent workmanship rather than me "learning from your mistakes"

My welding is getting better night on night though :naughty

I should be in a position to make the final welds to the brackets on my rear bumper tonight, wish me luck.

I'm using a Wolf MIG 140x with a cylinder of Argon :thumb2

 

[elty001]

Isn't a fiesta sill supposed to be a good match for the rear section.

 

[terranosaurusdoug]

Jim I'm in the same situation mate with my Maverick.

I'll be watching this closely so I can do the same to that :naughty

I hope it will be me copying your excellent workmanship rather than me "learning from your mistakes"

My welding is getting better night on night though :naughty

I should be in a position to make the final welds to the brackets on my rear bumper tonight, wish me luck.

I'm using a Wolf MIG 140x with a cylinder of Argon :thumb2

No welding thread?? Shame on you :nono..........:lol

 

[RJL Services]

i have just bought a pair of fiesta ones to repair my sills they look like the same profile as was mentioned in a earlier post i read 39.99 a pair delivered of ebay seem good quailty will get a good coat of shultz too

 

[jims-terrano]

Any chance of an eBay link please

 

[Terrano Steve]

If you are looking for a lasting repair I would replace the entire sill.
Welding 3mm flat or similar as Rick suggests is going to be easier than welding thinner material & is likely to distort less with heat.
I have removed entire sills & replaced them with box section before which works well & looks good if you choose correct size box.

 

[RJL Services]

ebay no. 190723453600 gone up a fiver in this listing

 

[jims-terrano]

Cheers, that’s another option isn’t it.

 

[Banshee]

ebay no. 190723453600 gone up a fiver in this listing

I've added that to my watch list :thumbs