[Mk2] [NA] sill restoration, where to start?

[MR2 Livvy]

I have removed the outer sills on my car to unearth a whole heap of problems RUST RUST and more RUST. I have cleaned away most of the rust and been left with well not a lot of inner sill. As I am welder and fabricator I thought I could tackle this myself. But now i am unsure as how to patch and strengthen the inner sills. Where to start and how much work is needed.

www.facebook.com/zoe.livingstone.98/med ... 093&type=3

I have taken lots of photos as i have gone along. I would be more than grateful if anyone could give me advice as to what to tackle first. Or how to rebuild those inner sills.

The part which im struggling with is the box part at the rear of the car, its perished and there is a huge gaping hole left. What would it have looked like before the rust invaded.

Zoe

[craig]

Have a word with Peter Gidden on here. He's sorted out a fair few rusty sills on MK2s, including mine.

Here's his profile:

http://www.imoc.co.uk/forums/profile.ph ... file&u=885

[MR2 Livvy]

Cheers i'll PM them. I'm trying to figure how all of this

www.facebook.com/photo.php?fbid=1015418 ... =3&theater

joins the car, I haven't seen anything other than the outer sill before and certainly nothing this bad

[Nic]

This thread on the subject may help http://www.mr2oc.co.uk/forums/41/148602.html

[aussieGT]

Thats some evil looking rust. And thats just what you can see.

I'd be tempted to find another car, probably less money spent and less tetanus injections needed.

redmr2 was doing their best to give a rust free shell a useful home - with a bit of luck they may still have it.

[MR2 Livvy]

Thats giving in too easily. A car of that age i was expecting damage. Im going to be replacing the really bad parts and treat it as much as i can. If i did buy another car i would prob expect to find the same problems. The sils are the biggest problem so far. Im doing the majority of the work myself. I havent spent a great deal of money so far. Im not sending into a garage to get ripped off.

[aussieGT]

If you are trying to save any parts - have a look at 'molasses to remove rust' videos on youtube.

Initially I thought it was some sort of inter webs hoax, but saw enough different videos to give it a try. Early days on the pieces I'm trying git out on but pretty promising results so far.

But - there's giving in too easily and there's realising when something is too far gone.

[abovetherim]

These may help you. The final pic is where i'm at now so any more pics you need just ask whilst it is still open





The bit behind the rear box is the inner arch. I was planning on putting the sill cover on first then build up the inner arch.
Give me a shout if you need owt

[MR2 Livvy]

Thankyou that helps me out loads. Now i know what it should have looked before. Im just wondering why the centre section of the inner sill has no box section beyond the end one like most pictures of sill repair ive seen. Yours has a middle section. Is this due to different models? Or been taken out?

[abovetherim]

Not entirely sure what you mean but then I have only seen inside my sill and the couple of threads I have read with pics generally only shows the rear end. If others don't have the same reinforcement then this could be tintops or moonroof and need less bracing????

Any how this is an interesting picture


Oh and on mr2oc Olly Dent can supply sill covers of full length that he had a coach builder make. £80 plus post iirc

[abovetherim]

Just had another look at your photos (didn't realise I could see them all, previously looked at first one). I think I do have more box section than you.

I can see the inner arch apron has been botched up previously! Have you had a peek at the sides behind the rear bumper as quite a few 2's succumb to rot there to.

Having just checked the pic specs, the one I posted before was from a JDM turbo. The pics for my tbar jdm N/A is the same as that but........ below is a uk 91-93 n/a


As you can see the reinforcement box sections 61425/6 and 61423/4 are absent from this pic

Edit: ok I have looked further and jdm coupe n/a has the reinforcement so I think they are absent from uk tintop (and maybe moonroof).

[MR2 Livvy]

Thats brilliant thankyou again. Ive just had a 8ft by 4 sheet metal delivered today. A plater who i work with has a a set of rollers guilotine and press so hes going to form a set for me. The rest is going to be used to patch up those horrid holes and reinforcement. I havent inspected the rear bumper yet, focusing on the sills first as that will take up a great deal of time.