Inner sill repair

[Twincam-Alex]

Hi All
My first post here. A family member 2002 k11 only 20000 miles from new started with a smallhole in o/s rear inner sill.
After a tap round with the hammer this was the next result.


Then cut out best I could.
The final welded result.

Looking through the holes you can see the boxing section is rusting. The outer sills are fine.

 

[K10-1988]

Hi All
My first post here. A family member 2002 k11 only 20000 miles from new started with a smallhole in o/s rear inner sill.View attachment 76843
After a tap round with the hammer this was the next result.

View attachment 76844View attachment 76845
Then cut out best I could.View attachment 76846
The final welded result.View attachment 76847

Looking through the holes you can see the boxing section is rusting. The outer sills are fine.

Hi Alex - You go 'diggin' you find holes,... LOL
(Who's workshop did you ue ?? ( Alan )
.

 

[Twincam-Alex]

Hi Alex - You go 'diggin' you find holes,... LOL
(Who's workshop did you ue ?? ( Alan )
.

I used another mates. Known them for over 40 years.

 

[slj_2003]

Good job on the repair
Mine needs some similar work doing on the inner sills, looks nearly identical to this.
What type of metal did you use for the replacement plates? And did it take long to fab them up and weld?

 

[Twincam-Alex]

Good job on the repair
Mine needs some similar work doing on the inner sills, looks nearly identical to this.
What type of metal did you use for the replacement plates? And did it take long to fab them up and weld?

I used 20swg steel, approx. 1mm thick. I used a vice and a mallet to put the folds in.
Pic 1 shows the first small hole. After tapping the sill with a hammer you can see the extent of the rust. I then cut out with an angle grinder, then made the plates.
A good coat of waxoyl or similar may be beneficial in side the sills.