Old mondeo MOT failure.... try and guess..

[SiPMerlin150]

I was presented this as one of the few welding jobs i get from my work place...

He's given me a right one to do and by looking at it, how can the owner not even notice the state of condition this was in... I don't know about you fellas, but I wouldn't even want to attempt jacking it up to change a flat tyre on the roadside for fear of loosing the jack and my fingers!!

2 sills have been ordered (yes both sides need doing) and the boss wants a 'quick' job of it, meaning not cutting away the rot, just prep the edges of the new sill and lapping over the old sill. Seam welded around all edges except for the bottom lip, which is to be plug welded every 2 inches...

Not really my way of doing it, even if its an older car (1997-1998) i would chop out all the rotted areas and start from there..but hey ho, i'm not the boss.

Enjoy the piccies! I shall try and take some more after the ordeal has been dealt with.

 

[rtbcomp]

Can you get the number plate in one of the pics so we know not to buy it if it should come onto the market.

 

[SiPMerlin150]

Can you get the number plate in one of the pics so we know not to buy it if it should come onto the market.

I know, but who buys 'R reg' mondeos now? especially the juice guzzling 2.0 petrol model its got around 100K + miles on the thing. It looks to have no more than 2 years left on the road.

 

[anto]

Had a friend bring me her fiesta and it was a similar mess.
Since i hadnt ever done a sill repair on my own car i said no to the job, once you start cutting rot on a Ford you might not have much or any of the car left.

 

[Wozzaaah]

If you're not cutting all the old sill away but plug welding the new panel to the old lip then it's a failure due to being inadequately repaired.

 

[Shedendman]

And i do hope your boss doesn't expect you to work on it with just the jack supporting it,get some stands etc under it fgs

 

[Justme]

If you're not cutting all the old sill away but plug welding the new panel to the old lip then it's a failure due to being inadequately repaired.

He is right.

spot welded joints are acceptable where the original panel has been replaced to an existing spot welded flange (provided the original defective panel flange has been removed). Stitch or plug welding is acceptable as an alternative to spot welding in these cases.

 

[SiPMerlin150]

If you're not cutting all the old sill away but plug welding the new panel to the old lip then it's a failure due to being inadequately repaired.

yep...i'm afraid thats whats going to happen... as a matter of fact, i'm not at all happy with what i've been told to do... Tommorow i will try and 'persuade' him to allow me to do a more thorough job.... hopefully the old inner sill lip will crumble away and that will mean it will have to be done properly.

Persuading the old sill lip with a hammer....

 

[SiPMerlin150]

And i do hope your boss doesn't expect you to work on it with just the jack supporting it,get some stands etc under it fgs

Oh no, definately not! I jacked it up to have a better look at what I was dealing with. Since those pictures have been taken, the car has been moved to a corner of the garage and axled standed, whilst we wait for the new sills to arrive.

 

[SiPMerlin150]

Had a friend bring me her fiesta and it was a similar mess.
Since i hadnt ever done a sill repair on my own car i said no to the job, once you start cutting rot on a Ford you might not have much or any of the car left.

Too true!

 

[the snooper]

where is this garage do tell so we can avoid it and the boss's bodges

 

[atomant48]

I'd be trying to find out what that yellow line has been drawn with as all the rust seems to have been confined below it? Must be a good barrier of some kind.

 

[arceyered]

I had to repair an overhead gantry crane many years ago,the block had smashed into the rope pulleys .
Because of this the ropes were sliding over the jamed pulleys, I pulled the fuses and put a do not use notice on it.
The boss told me to replace the fuses I said no and worked through the night to repair it, three mounths later I was made redundant.
But I did not have to stand before the HSE after a accident, and answer questions, being the last competant worker to work on it.
It sucks when bosses won't let you do your job correctly and it is more often than not more cost effective.

 

[SiPMerlin150]

I'd be trying to find out what that yellow line has been drawn with as all the rust seems to have been confined below it? Must be a good barrier of some kind.

yeah! its the mot testers crayon to mark failure spots

 

[SiPMerlin150]

where is this garage do tell so we can avoid it and the boss's bodges

Can't really tell incase boss stumbles across this but, today i saw him chop away the old sill and the inner sill like was all good! One side has been tacked into place but then the mig broke down... turns out to be the wire speed circuit board, so it was dropped off at BOC for quotation for repair....