Rust and The SW20

[Mike]

The Rev2 yet again passed its MoT at the weekend, very pleased. However, the sills are getting pretty bad towards the rear now. They were highlighted as an advisory and the tester told me that they will almost certainly fail next year.

So, having heard snippets of rust horror stories over the years, what is the reality of rusty sills on the SW20?

Would welcome any sound words of advice and first hand experiences anyone would like to share.

Thanks

[ryan]

Not pretty reading

http://www.imoc.co.uk/forums/viewtopic.php?t=165190

[alanmr2turbo]

i did my mates this year. They didnt look bad till i cut them off and then found all the inner strenghening needed doing as well.

3 days of welding and making up plates

[Super_red]

Pretty bad like all cars this age subjected to salted roads, this was a blister the size of a 20 pence about 3 months after it passed an MoT



All the inner panels at this point were rotten through so the blister on the outside was the last thing to rot but the least important.

[alanmr2turbo]

arghhhhhh that brings back memories, yours are almost as bad as my mates

[ryan]

I wonder if theres a pattern to this tin tops Tbar, drainage points, different sill structure perhaps with Tbar chassis strengthening?
One of my MR2s went like this and it was a Tbar. I find it hard to believe that the sponge sinking within the seatbelt panel could cause such extensive rust to the inner sill. How the hell can the sponge get that wet?

[Mike]

So what are we talking price wise, in a worst case type scenario?

Would hate to lose my car to rust, the rest of the bodywork is in great condition for a car of its age, and the engine is still strong despite having covered nearly 130k.

No idea what I would replace it with.

[Super_red]

Mine is a tin top. The sponge was soaking wet and the water comes in around the wheel arch on mine at least as the panels in that area are not sealed.

[ryan]

Mine is a tin top. The sponge was soaking wet and the water comes in around the wheel arch on mine at least as the panels in that area are not sealed.

Where in the wheel arch, can you take a photo, the flexi sealant stuff failed?

[ryan]

So what are we talking price wise, in a worst case type scenario?

Would hate to lose my car to rust, the rest of the bodywork is in great condition for a car of its age, and the engine is still strong despite having covered nearly 130k.

No idea what I would replace it with.

im sure it cost Rob (see secondary link in the link I posted ; sends you to mr2oc) £800 and the company did a great job!

[Mike]

So what are we talking price wise, in a worst case type scenario?

Would hate to lose my car to rust, the rest of the bodywork is in great condition for a car of its age, and the engine is still strong despite having covered nearly 130k.

No idea what I would replace it with.

im sure it cost Rob (see secondary link in the link I posted ; sends you to mr2oc) £800 and the company did a great job!

Ouch, the ECU and mapping will have to wait then!

[craig]

Had my trims off and had a look

Driver side:



Passenger side








Sills are all good though, so will get that lot treated with POR

Doesn't look nice though

[Rob]

Cost me £600, not £800 and yes they did an awesome job. Mine is a moonroof model, so it affects all types.

[craig]

Cost me £600, not £800 and yes they did an awesome job. Mine is a moonroof model, so it affects all types.

Yep, mine in the pics above is a tin top.

[ryan]

Cost me £600, not £800 and yes they did an awesome job. Mine is a moonroof model, so it affects all types.

Thanks for your input Rob

[Rob]

No worries.

I think the problem is partly the foam, but mostly the wheel arch metal going a bit porous over the years. That is where mine first went through on the screwdriver test...

[alan_uk]

mine is a rev 5 moon roof and i had soaking wet sponges and a lot of rust had it cut out and plated resprayed stone chip coated then my skirts fitted all in cost £400 but the guy was a mate and it all started as a few little blisters :S

[John145]

The rear end of my 2 is fairly well rotten, doubt it'll be on the road by the next MOT

[Marlowe]

My rev2's pretty good in this aspect, but I'd like to keep it that way. I plan to keep it off the road in Winter for the reason Super_Red stated.

Is there any way of removing the foam to pre-empt?

Also, a side note, but If it's any consolation modern cars have the same problems - my 06 plate GTI had the common VAG fault of foam in the front arch trapping water and causing rust which lead to a warranty claim for a whole new wing (after a lot of arguing with VW UK who didn't want to honour their own warranties...). It was common across the range and I think they replaced the foam with sealant as a result - but only on 10 onward cars.

[Loque]

Good God this is scary reading.