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Sill replacement

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Looks like I need both rear sills and the bottom of the drivers outer sill. This was the result of my screwdriver poking today. Looks like the rear sills have been bodged in the past, the hidden side of the sill was full of flexible filler that has trapped all the mosture and rotted them out.

http://i131.photobucket.com/albums/p281/flipatron/000_0651.jpg
http://i131.photobucket.com/albums/p281/flipatron/000_0650.jpg
http://i131.photobucket.com/albums/p281/flipatron/000_0649.jpg
http://i131.photobucket.com/albums/p281/flipatron/000_0648.jpg
http://i131.photobucket.com/albums/p281/flipatron/000_0647.jpg

The good news is that the rest of the bodywork is fantastic, not rot at all from what I can see.
 
Can you buy replacement rear sill sections (inner and out) either genuine or pattern as the fabrication required in this area looks quite difficult. I'd like to keep the shell 100% as it left the factory if possible so will need to fabricate the water drain indent at the rear of the sills and also the drain holes for the outer sill.
 
Porsche sell the inner and outer sills (outer sills cost £130) but the section after the crease below the door line is all part of the rear quarter panel.

www.clubautosport.co.uk sell a patch panel for the rear quarter part so as long as the rust is confined to the area under the bumpy stonechip paint then it can be cut out and welded on
 
The good news is that the rest of the bodywork is fantastic, not rot at all from what I can see.
Click to expand...

Looks bad, but not unusual. I wonder how many other cars have exactly the same hidden problems! [:eek:]

As Paul says, proper cill panels are available and not too dear. Properly repaired, and regularly treated, and you'll have another 20 years out of them!

 
Prices for the work are in.

Bodywork
Both rear sills and the drivers outer sill replaced to a very high standard. both sills treated with wax protection - £400.

Paint
Re-coat lower sills with stoneguard and paint in Guards red - £200.

I visited the fabrication guy today to view his work and I have to say was very impressed. Looks like the repair to the outer sill will require almost no filler when finished! I've decided to source a genuine Porsche outer sill for him to fit, It's an extra £130 but I think It's worth it.

The paintwork guys also seem very good, ex BMW. I may also get a price for the front wing (been painted in the past and looks a little orange), the front spoiler (small amount of damage), front badge panel and headlights (stone chips).

I've a set budget in mind for the welding and paint so I'll have to see what's left in the kitty. Car goes in in a couple of weeks so I should be on the road mid May. Hoping to get some pics done during the work which I'll post up.

I've also got one or two dings in the bodywork and wondered which dent removal firm people have used in the past.
 
I have used Dent Devils check the web site . If you are near Lutterworth the local guy Barry Ellis 07718 652812 is excellent. He has worked on many of my familys cars and have been pleased with all. A lot depends on the individual get recommendation
 
I also use Dent Devils. The chap that covers Northampton has been doing it over 10 years and really knows his stuff. Whoever you use, ask how long they have been doing it and if your particular dents can be removed invisibly - not all of them can, depending on location and size
 
Anyone know where I can get a genuine outer sill other than direct from Porsche? I've heard they can be bought for around £80 but from where? Need to order it as the 944 will be with the restorer soon.
 
the only ones I have seen are these

http://212.67.202.62/~clubauto/porsche_944_repair_sills_and_low.htm
 
I'm trying to avoid the cheap sheet metal ones.

You can buy a genuine outer sill from an OPC for £157inc vat. Anyone know where I can get one cheaper? I'll be ordering the Porsche one tomorrow if I can't find one as the fitter needs it for Tuesday.
 
I think mine may have been a little cheaper, but not much (and they were bought last year). For the lowest price I would recommend trying Exeter OPC, they put a lot of effort in and offer some great prices. If you're a club member they'll do you the usual discount on top too.
 
Well I took the car for its repairs on Monday. Its the first time I've driven it since I drove the 4 miles home. Have to say it was a horrible journey, after 5 mins there was a small knocking noise from the passenger side which got louder and louder. Thoughts of replacement gearboxes and driveshafts were in my mind but on arrival at the garage I was quite relieved to discover five loose wheelnuts! I'd forgot to tighten them after cleaning the wheel.

The repairs are well underway, the passenger side is almost done (looks good) and the replacement sill is arriving from Porsche on Thursday (£131+Vat).

Got my insurance sorted on Saturday, £204 with £50 excess which I didn't think was to bad until I received a written quote (to late!) from RH Specialist Vehicles for £123. I may cancel it and go with RH.

Anyway, I should be on the road this weekend or early next week, can't wait.
 
Well the new outer sill finally arrived at the bodyshop on Friday (OPC promised delivery on Thursday, don't ask!) so it should be back with me, painted and rust free by mid week.

Here are the latest pics from the bodyshop, looks like he's doing a fantastic job.

http://i131.photobucket.com/albums/p281/flipatron/944sill2.jpg
http://i131.photobucket.com/albums/p281/flipatron/944sill3.jpg
http://i131.photobucket.com/albums/p281/flipatron/944sill4.jpg
http://i131.photobucket.com/albums/p281/flipatron/944sill6.jpg
http://i131.photobucket.com/albums/p281/flipatron/944sill5.jpg
http://i131.photobucket.com/albums/p281/flipatron/944sill1.jpg

Thanks to Pete at OPC Chester ( if he comes on here) for hand delivering the sill on Friday.
 
Looks good Philip. There's something terribly wrong though, bodywork really isn't supposed to be finished this quickly [:)] [;)]
 
Nice quick turnaround, well done [8D] If you are happy with his work then I think he will get quite a few new 944 customers as part of your recommendation

Hope you get it back on the road soon.
 
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