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 Post subject: How To - Repair Sills
PostPosted: Wed Oct 03, 2007 10:19 pm 
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Well after some delays finally it got started today.......


Firstly, decide if it needs work, this one quite obviously did :!:
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Secondly get an ace welder man, I'm lucky that a Spiderpig lives close by :lol: And get a sill from your local panel supplier, ( cheaper than Hadrian!)
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Draw around the new sill...
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Remove the rotten part...
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Cut the new sill to match the gap..
Imagee new sill to match the gap..

Looks like its been repaired before :roll:
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Bit of access required... Jack it up, ( be sure it is secure :roll: )
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Offer the new part to the car
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Weld it up along the edge
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Grind the weld flat
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Looks good :P
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Awkward corners and edges....
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Use cardboard for templates in hard to reach areas
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Some spare metal for the plate
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Weld it in place
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Weld the bottom seam
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And thats it for today...
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To recap, you will need

1. Rotton sill
2. New sill
3. Ace welder and kit
4. Tea and tabs for the ace welder
5. A grumpy neighbour to complain your drive is a garage ( I wish I had taken a pic, cause he is a whingy nothing better to do neighbour!)

Bit more filler welding, another grind, some bodge to set the lines and paint. Job will be agood one.

** Brought to you by Streakers rotton Turbo and Spiderpig ( who did all the work :wink: ) colaboration **


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 Post subject:
PostPosted: Wed Oct 03, 2007 11:03 pm 
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Awesome write up Andy Thanks *Sticky'd* and moved to "Bodywork" hope that is ok - this should prove useful too many 4Gers :top:

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 Post subject:
PostPosted: Wed Oct 03, 2007 11:58 pm 
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:top: fookin mega read :OD


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 Post subject:
PostPosted: Thu Oct 04, 2007 10:20 am 
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Nice work.

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 Post subject:
PostPosted: Thu Oct 04, 2007 5:07 pm 
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Top Work :top:


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 Post subject:
PostPosted: Sat Oct 06, 2007 12:23 am 
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thanks for the props guys...
honestly it looks simple but a bit of forethought is required...but dont let that put anybody off mind.
it's only when we got to the actual fitting that we found the new sills had a slightly different shape to the oe ones...which is where the bodgetastic skills came into play :wink:
just the other sill and wheel arch to do next :evil:


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 Post subject:
PostPosted: Sat Oct 06, 2007 7:58 am 
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Nice work Rob top job!

Spider pig, Spider pig, can he weld to a Civic... :lol:

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 Post subject:
PostPosted: Sun Oct 07, 2007 7:56 pm 
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Top bombing.
I'm glad the shuttle has plastic sill covers. Daren't go in.
I made my own sills for the Astra with sheet metal. But it didn't have to be pretty, but used a bit of filler on it. Need to rebuild the arches next :shock:

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 Post subject:
PostPosted: Sun Oct 07, 2007 10:13 pm 
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nominous wrote:
Top bombing.
I'm glad the shuttle has plastic sill covers. Daren't go in.
I made my own sills for the Astra with sheet metal. But it didn't have to be pretty, but used a bit of filler on it. Need to rebuild the arches next :shock:


I'm with you on the plastic sill covers - "out of sight out mind" right Dave?!? :shock:

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 Post subject:
PostPosted: Sun May 25, 2008 8:47 pm 
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glad i found this post coz i gotta have new sills fitted
cheers man :D


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 Post subject:
PostPosted: Sun May 25, 2008 10:11 pm 
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nice !


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 Post subject:
PostPosted: Sun May 25, 2008 10:21 pm 
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exaclty how i fitted mine except i did the arch at the same time lol

nice read!!

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 Post subject:
PostPosted: Fri Oct 31, 2008 5:20 pm 
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How do you stop the panels buckling due to heat, especially the larger panel when you are doing the arches?

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 Post subject:
PostPosted: Sun Nov 02, 2008 10:44 am 
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EE9 CVC wrote:
How do you stop the panels buckling due to heat, especially the larger panel when you are doing the arches?


Go slowly. Bit of weld at a time. 'Spot' first then fill in bit by bit.


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 Post subject:
PostPosted: Wed Nov 10, 2010 9:29 pm 
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cryz2 wrote:
never had a problem , with my arch

just spot welded and then joined the welds

if i was going to do it again , i would use a under lap tool / hole punch

that i now have :oops: :oops: :oops:

i wish i had it before i started


A hole punch or a drill, I drill holes at about 50mm spaces along the bottom and fill the holes with weld like spot welding for a neat join to the inner sill. Be interesting to see someone do a how to on inner sill repair, for when the rot goes through the inner and theres nothing to weld the outer to!


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