Mk2 - my sill restoration experience

[adam3442]

Pretty cheap Rob, I can see how many hours went in to that repair and the level of fab required. Nice welder too!

[doeboy]

Glad you gotit sorted rob and not to bad, sup rising amount of rotten metal came out of her mate, will be getting the foam outta mine ASAP.
Good work mate.

[rob]

Welding certainly is an art, one I would love to learn if anyone knows of a good course around my way?

[d-peg]

From somebody involved in sheet metal fabrication on a daily basis - that is top notch work

Like you said - above & beyond

[jimi]

As you might have read, back in May I discovered that the Mk2 MR2 is not as immune from rust as I had thought.

I can remember (not so long ago) MK2 owners used to be fond of telling us MK1 owners how MK2's didn't rust ! it seems our prediction that the MK2's turn was coming was pretty accurate.
MK1 owners have been dealing with the results of Mr T's use of foam in the bodywork for years, it's the main cause of the MK1 rear arch rust problem.
You've gone the right way about dealing with it As any experienced MK1 owner will tell you, the only way to deal with it is to cut it out and put in new metal

[d-peg]

.... As any experienced MK1 owner will tell you, the only way to deal with it is to cut it out and put in new metal

Couldn't possibly agree with this strongly enough. The only way to deal with through & through rust is to cut it out. Surface rust can be cured to prevent if spreading further but will be a repeat offender. Painting over rust only gives a nice protective bubble for the rust to work in. Lose it via angle grinder or panel replacement as done here

[Protok]

This is very good

Belongs on KY2 I think

[MRPagey]

I fabricated some sills for his MR2 from flat sheet metal. To get the curve we hammered it around a Oxy gas bottle. The ends were done with cutting and welding. It took time but it looks original. I wouldn't want to be doing if again though!

[rob]

Thanks for the input chaps, good to know you all approve. Hopefully this might encourage others to get the work done properly (ultimately saving you money over a cheaper job that isn't done properly).

Jimi - yeah I will put my hands up and admit that I was one of those who thought the rust was limited to the Mk1. It doesn't seem as bad on the Mk2, but nonetheless bad enough to take it out of the average DIY-ers hands.

Still, it could be worse. PBCM's current car (they tend to have 2 in the workshop at any 1 time) is a 60's Alfa Giulietta Spider. It is almost beyond the point of redemption - they are literally reconstructing every structural piece and are doing a stunning job!

[jimi]

To get the curve we hammered it around a Oxy gas bottle.

like taking risks do you ? I wouldn't advise anyone to do this

[d-peg]

To get the curve we hammered it around a Oxy gas bottle.

like taking risks do you ? I wouldn't advise anyone to do this

Or ANY gas bottle for that matter! But you really picked the worst one!

Vid of proper scary sh!t
http://www.youtube.com/watch?v=uUmLe9WCXX0

[MRPagey]

Empty with the valve removed I might add! What do you take me for?!

[d-peg]

Empty with the valve removed I might add! What do you take me for?!

A rhetorical question yes!

[MRPagey]

We all know where you order things from Dan so sush!