Rust in sills - Is it bad??

[Rabs]

hi,

hoping you can let me know how bad you think this could be....



Here is another shot



I am hoping that I can grind it back, treat it with Por 15 and then fill, prime and paint.

My concern is that it will have spread to the inner sills. Any thoughts?

I also have some rust on the bottom of the offside front wing near the sill. Here it is



Is this going to be worse from the inside?

Any help or advice would be most appreciated.

Thanks

[Duke137]

Needs cutting out and metal welding in, unless you are selling it then its P40 all the way.

As a general rule, what you see is usually the iceberg tip (10 - 20%).

Good luck

[Rich320I]

lift the carpet inside the car and have a look, but with out looking at it id say pretty certainly yes theres more rust lurking behind what you can see they bud,

[Grrrmachine]

That will definitely have spread inside, and you will have a hole in both the inner sill and the floorpan (it's a sort of triple-layer joint under the door).

Filling it with fibreglass is dangerous. Fix it properly with fresh metal.

[si911t]

I would agree with the above, get some cut out and fresh metal on it.

[Rabs]

Had the carpets up today and it is all looking good. Inner sill ok and the floor pan is fine. Under the car is looking good also so pretty bad surface rust really. Have put a wire brush to it and have cleaned and treated with Por 15 rust treatment. Plan to fill and prime it tomorrow. Fingers crossed. Thanks for your advice. Will upload some photos shortly of it after Por 15 treatment.

[aimlessrock]

That rot in the still is certainly not surface rust....Rabs it needs new metal letting inn!

[Grrrmachine]

Agreed. If you fill and paint that, you'll have fresh rust bubbles before the year is out.

[DanThe]

hi,

hoping you can let me know how bad you think this could be....

Now dont think im being harsh or trying to offend etc etc, but thats a foooking hole! Surface rust happened there about 6 years ago

Looks like the sill trim has been hiding most of it

[Brianmoooore]

I've just done this repair on both sides of the cab. in my workshop at the moment. Took about half a day to cut away the rusted metal, cut a similar shaped piece from a four door shell and to weld it in place.
In my case, at least, there was no serious rusting to the underlying metal.
The cause of this is water getting into the rear window area, and running along the top of the main sill. If it runs backwards it rusts the front of the rear outer arch, or if it runs forwards it causes the damage that you have.
When the welding is complete, remove the rear window, and you can reach down inside to paint, seal and wax the repair from behind.
The rust at the bottom of the wing is trivial, but it's worth unbolting the wing and dealing with it properly.