MR2 MK2 sill repair - cheap panel!

[Pigeon_Droppings]

Typical...when I don't put etch primer on I end up leaving it a couple of weeks...when I do I get to carry on the next day! Today I put in the bottom of the box reinforcement. This was originally spot welded in place with 4 spot welds...I decided to lap weld along the back. Went in OK-ish. I find it really difficult to weld upside down so it's always a bit messy. Top part went according to plan...I had a few holes in the corner where I couldn't really get in that easily...had to give the pigeon a squeeze to fill in the holes...luckily I could get a copper plate behind from inside the car. Next job will be to get the rear sill inner arch piece made up and welded in...not looking forward to that as the drivers side was a royal pain.

 

[Pigeon_Droppings]

And a few more...I cut the lower corner back deliberately and left it open...the idea is that any water that does get in will flow down into the sill and out through the drain holes. Overall went OK today but was one of those days where it's a bit of a hassle.

 

[Pigeon_Droppings]

Got on with the inner arch sill piece today...this was the bit I really wasn't looking forward to as its a complex shape plus it needs to be well aligned with the outer sill. Started by making up a template of the piece I chopped out. I took it out in one clean piece so I'd have it in one piece to copy. I think this is the most complex piece I've attempted to make...on the drivers side it got a bit messy and I wanted to do a better job this time. As you can see the original was well shot...held together by rust and stonechip!

 

[Pigeon_Droppings]

Decided it would be a game of two halves...I used some masking take to make up a template that I could use to cut the new steel.

 

[Pigeon_Droppings]

and the other half

 

[Pigeon_Droppings]

Tacked the pieces together ....then used the stop/start technique to join them

 

[Pigeon_Droppings]

Was very happy with the fit...it pretty much fit first time. I clamped the outer sill over the to and use this as a guide to adjust the fit. Initially tacked then joined between the tacks...I went for a lap joint so welded both sides of the lap. I was worried I didn't get enough penetration from the inside of the arch...any opinions welcome please.

 

[Pigeon_Droppings]

Finally some etch primer to keep the rust off it. Have had some good progress the last few days but I think it's going to be a while until I get down the garage again...next job is to fit the outer sill.

 

[Pigeon_Droppings]

OK - as it turns out putting the etch primer on was quite a good idea as I haven't managed any time on the car for quite some time. Got down the garage for an hour this evening...have made some progress on cutting the sill repair panel ready to butt weld in. I had quite a bit of difficulty with the inner arch (again!!!) and ended up persuading it with my persuading tools...next job is to check that the inner arch aligns to the outer sill...cover everything liberally in POR15 and then butt weld the outer repair..

 

[octo0072000]

looking good

 

[Pigeon_Droppings]

Cheers mate...had a bit of fiddling around with the inner arch where it joins the outer sill at the rear of the sill. OK so I reckon all sorted...all welded up ready for the outer sill to go on. I put a coat of POR15 on there...also ended up cleaning the welds up a bit...they were fouling the outer sill and I had a moment! Would have done it over the weekend but sods law...of course the gas is now run out...typical!!

 

[Pigeon_Droppings]

Had a good day today...finally got the outer sill back on and "mostly" welded in...was a real pain in the "butt"...I kept blowing holes and having to tweak the settings plus take lots of time to avoid putting too much heat into the panel. Plug welds went very well..guess it helps having taken out all that rust. Still quite a bit to do....grinding down the welds plus sorting out the inner arch which needs trimming back, cleaning up and welding...am going to seam along the inner edge. Gas held out...but not sure for how much longer...hopefully enough left to get the few bits done.

 

[Pigeon_Droppings]

Managed a stint today and got a fair bit done...spent an age grinding down the welds and cleaning up...cut the inner arch curve to match the way it looked originally. Decided to plug weld in the end...just too much faffing to get in there and get burnt...the original was spot welded anyway.

 

[Pigeon_Droppings]

Stuck some etch primer on there...I think I managed to squash the end of the sill a little with my clamping so will need to sort that out with a little filler...bit of a shame.

 

[Pigeon_Droppings]

Finally the sill is finished...having done the drivers side I thought it was going to be easier the second time around....well I have to say it wasn't!! Here are a few pics with the trim panels back on...next job is to make a start on the passenger side rear arch / quarter panel. This side looks alot more solid so fingers crossed it's a quick repair.....famous last words!!

 

[Matt S]

That looks fantastic I take it you had to use a skim of filler on the outside? Looks like you were never there!

 

[Pigeon_Droppings]

Hi Mate...yep I used a little filler along the top edge and the join...over the butt welds...I was worried about grinding off too much of the weld as I didn't want to weaken it...also a little where I put a dent in the rear of the sill when clamping the inner arch to plug weld the wheel arch flange. Overall I'm happy with it...likely the car will be going in for paint in the future so this is just to keep it presentable and protect the repair....I'll also be waxing all of the sills inside but that will be after all the repairs and mot etc....don't want to end up having to remove the wax once it's in.

 

[Pigeon_Droppings]

Managed a bit down the garage today...fortunately I have a few days off work this week...unfortunately it's about 30 degrees and my garage has a steel roof so it's like an oven at the moment! Cut out the lower part of the rear arch...much the same as the drivers side unfortunately....actually it's a little less severe hence I took out a smaller piece of the outer panel. I did think about trying to weld in a patch from inside the arch....but figured it would be difficult to do a neat job in such a tight space plus I'd only be able to get to one side of the repair....actually this is what I originally tried on the drivers side so learned that lesson the hard way already!!

 

[Pigeon_Droppings]

Started repairing the piece that came out...then the welding gas ran out which stopped play. Hopefully Barnet can turn around my refill tomorrow....still need to make up the inner arch patch so will have something to do tomorrow. Although the steel was still in one piece some areas were paper thin and trying to weld them on the car would have been a total nightmare...in the end I decided to remove anything I wasn't happy with...still need to finish the welding off so this is a work in progress.

 

[Pigeon_Droppings]

While waiting for the gas to arrive (the guy got stuck in traffic...but hats off for next day delivery...I only ordered it at 6pm yesterday via their website)....got on with the inner arch repair. Based on past experience I decided it's much easier to make up the repair THEN cut out the old metal...makes it much easier to form the repair on the car vs trying to match a piece of rusty steel on the bench...live and learn.