Menu toggle

oh my god help

robdimond

robdimond

PCGB Member
Member
Picked at a scab. It appears my driver side sill is sculpted out of filler. Someone has welded a thin repair panel over the rusty metal and just bogged it down with filler. I could cry.

Good news: Inner sill looks ok. Just a semicircle shaped poor repair at the rear.

IMG-20130817-00357_zps82849b9e.jpg


IMG-20130817-00360_zps0adc2b03.jpg


IMG-20130817-00361_zps3580541e.jpg


IMG-20130817-00358_zpsb341d485.jpg


The bottom of the sill is gone so I don't think I can really use anything except the proper original sill panel. Let's hope I can get one...

What else should I disassemble... can I unbolt the rear trailing arm where it mounts to the sill without dropping the rear beam?

Is the car OK propped up how it is or should it be on it's wheels?
 
Rob, mate, I've got bad news for you - the driver's side outer sill has dropped off! [:eek:]

That was some scab picking you did, but you have managed to leave a nice tidy edge all 'round, which will make welding the replacement in much easier ...

[;)]


Oli.
 
It's not as bad as it looked at first.
The floor is in good shape.
The intermediate sill panel I've cut out the crap repair to leave a neat fist size hole to patch up... the rest of it is good.

The filler was 5mm thick in places.

Repairing the inner arch is the only bit I'm worried about because it's dissolved and I've no shape to work to. Will dig up Colin's photos (and where are you Colin in my hour of need I need your moral support on this one!!! [:D])
 
Just ordered a drivers side sill from OPC Cambridge, 140+VAT

Intend to do the replacement myself and post up the pics here.

Also heard that Porsche have allocated a new part number for the passenger side. Apparently that means they've found a new supplier and these parts will be available again soon! So hopefully more will be saved!
 
Rob It doesn't look too bad. A new sill and you'll have it back to full health in no time.If you need any help or just a shoulder to vent your frustrations on give me a call.
 
Some progress:

HammersmithandFulham-20130826-00370_zps43b091e7.jpg


IMG-20130826-00367_zps7fed83ad.jpg


Made up a section of wheelarch and tacked it in. Welded in the inner panel repair section. Not sure I've got the shape right might need a couple of goes...

Started to remove the front wing by taking out those three bolts hidden in underseal behind the ABS pump (what a nightmare!). Managed to chip some of the underseal off so could get a socket in on a long extension.

Cheers Colin... looking at your photobucket your car was quite a bit worse... don't know how you did it!

Any tips for removing the door (esp the wiring loom) because that's the next job. With the front wing and door off I can then get the rest of the sill off.
 
Good job Rob. All I would say is you need to dress your welds down more . You should sand them flat so they cant be seen them prime with zinc primer ( zinc 182 ). It just keeps the rust at bay that bit longer as a panel will rust at the weld first.
 
Thanks all. Good tip Colin... I will dress the weld back so that it looks nice on the inside. I'm going to struggle to do the back side of that weld because there is a car in the way... I tried to squirt lots of zinc primer in there.

Did you plug weld the sills on?
I was thinking about hiring a spot welder, but the HSS one needs a 32A feed. I wonder if I can find a mobile welding guy just to do the spot welds?
 
Yes I plug welded along the top and across the bottom. I tried to use a spot welder but as you are going through 3 skins you need a serious spot welder to do it right. Also I found it very difficult to get the tips of the spot welder into the bottom edge of the sill due to the profile of the panel. The higher you can get the car the easier it is to do the bottom edge.
 
Searching for tips how to make repair panels I found this. Pretty amazing what people can do!

http://retrorides.proboards.com/thread/70135/panels
 
Not going to lie, I could spend all day reading that thread - really has some good welding and finishing skills.
 
It looks worse before it looks better!!

IMG-20130901-00374_zps08db7112.jpg


Getting the front wing off is a bit of a mission. Need to repair the bottom of the wing and also a little rust spot at the bottom corner of the door skin.

Door off next and then the rest of the sill...
 
While you are in there Rob. Have a really good look round the inner wing and front bulkhead, If you see any scabby looking under seal pick it off and have a poke around. I found a few wee holes etc in that area that were really well hidden by the underseal.
 
You must log in or register to reply here.

Posts made and opinions expressed are those of the individual forum members

Use of the Forum is subject to the Terms and Conditions

Disclaimer

The opinions expressed on this site are not necessarily those of the Club, who shall have no liability in respect of them or the accuracy of the content. The Club assumes no responsibility for any effects arising from errors or omissions.

Porsche Club Great Britain gives no warranties, guarantees or assurances and makes no representations or recommendations regarding any goods or services advertised on this site. It is the responsibility of visitors to satisfy themselves that goods and/or services supplied by any advertiser are bona fide and in no instance can the Porsche Club Great Britain be held responsible.

When responding to advertisements please ensure that you satisfy yourself of any applicable call charges on numbers not prefixed by usual "landline" STD Codes. Information can be obtained from the operator or the white pages. Before giving out ANY information regarding cars, or any other items for sale, please satisfy yourself that any potential purchaser is bona fide.

Directors of the Board of Porsche Club GB, Club Office Staff, Register Secretaries and Regional Organisers are often requested by Club members to provide information on matters connected with their cars and other matters referred to in the Club Rules. Such information, advice and assistance provided by such persons is given in good faith and is based on the personal experience and knowledge of the individual concerned.

Neither Porsche Club GB, nor any of the aforementioned, shall be under any liability in respect of any such information, advice or assistance given to members. Members are advised to consult qualified specialists for information, advice and assistance on matters connected with their cars at all times.

Porsche
Lockton
Pirelli
Officially approved
Oracle Finance
WEX Esso
Collecting Cars
Archant Dialogue
Back
Top