How would you repair this sill?

[conor1n]

Hi folks,

My project thread is here, but I would like to post this thread over here to see how you guys might approach repairing the rotten corner/sill, which started off as a mashed jacking point.

I'm wondering to what extent I should cut back as it seems that some people are telling me not to cut any more but I think that will result in a half assed fix, and be difficult to weld.

Any body got any pics of a repair they did?

Thanks a lot..
Conor

 

[Bluebeard]

Just keep cutting until you get to clean metal all round. That’s the only correct repair.

 

[conor1n]

Just keep cutting until you get to clean metal all round. That’s the only correct repair.

That's true I guess.. my problem is that I have some guys working near me who say I have already cut enough (Or too much...). They are wayyyy more experienced that me but I don't know how they can stand by that since there is clearly some rot there.

 

[PhillipM]

They probably just slap patches over things for the MOT and that's it.

Cut it back square to clean, sound metal. Make your life easy.

 

[conor1n]

Yea I've been looking at this. I think it should be more straightforward to cut out a bit more to be nice and square and give some space.

Then build it back up, piece by piece.

They probably just slap patches over things for the MOT and that's it.

Cut it back square to clean, sound metal. Make your life easy.

 

[conor1n]

.... over the weekend, I went from this ....

to this.... and it felt good!

 

[PhillipM]

For me, personally, anything at all that has to be bent or flexed out to clean up, gets chopped out to thick, sound metal and replaced, you'll never get it quite back right because the metal stretches, especially when it's thin and corroded.
The only exception is when I work on classics/vintage cars where the owner is trying to keep as much of the original paint, etc, as possible.

 

[conor1n]

For me, personally, anything at all that has to be bent or flexed out to clean up, gets chopped out to thick, sound metal and replaced, you'll never get it quite back right because the metal stretches, especially when it's thin and corroded.
The only exception is when I work on classics/vintage cars where the owner is trying to keep as much of the original paint, etc, as possible.

I am inclined to agree with you there.

 

[PhillipM]

Yeah, I would have just lopped that entire corner out, rebuilt it panel by panel.

 

[conor1n]

Yeah, I would have just lopped that entire corner out, rebuilt it panel by panel.

I'm thinking that's the way it's going if I am honest.