51 replies to this topic

[sonscar]

My son bought this car 17 years ago fitted with freshly filled oversills fot its new MOT.He has just given it to me as with two small children he cannot afford to run it.  002.JPG   83.45K   3 downloads  004.JPG   45.2K   4 downloads  008.JPG   76.03K   1 downloads  009.JPG   71.22K   2 downloads.The original sills had been removed and rust treatment applied but it is evident that the double skinned overlap received none of this and was very rusty.As this car was his daily and lived outside it has lasted 17 years like this,longer than some did from new.Cutting out and repair to follow.Steve

[sonscar]

So some cutting started  007.JPG   57.92K   2 downloads  005.JPG   70.09K   0 downloads  012.JPG   79.03K   0 downloads  009.JPG   32.13K   1 downloads

[sonscar]

replacement started  001.JPG   52.55K   1 downloads  002.JPG   46.41K   1 downloads  003.JPG   55.07K   0 downloads  005.JPG   28.76K   0 downloads  007.JPG   43.98K   1 downloads  011.JPG   32.68K   2 downloads

some finishing welds over the screwholes and ready to paint.Next the other side.Steve

[sonscar]

Whilst the door was off I saw this fat patch on the door post,rust between a double skin.Almost tempted to ignore it but I had to poke it.  001.JPG   64.85K   1 downloads  002.JPG   64.93K   1 downloads  003.JPG   63.88K   0 downloads  005.JPG   71.72K   0 downloads

Looks like someone had been here before.Will repair today.Steve..

[sonscar]

patch welded in ready to dress down.I would like to paint the repairs but it is cold and I cannot find the drive to do it yet,so will epoxy primer it and wait for paint until the other sill is done.  001.JPG   56.12K   1 downloads

[sonscar]

Passenger side sill and an old repair that I did is going to cause me some more effort.When rust between the oversill and floor burst through in several places I cut the affected floor and the inner sill to the doorstep out.I cut the oversill to  the pressed flutes and welded the together almost like a proper sill.As the rear was ok I left it at that.Now the rear has burst through so I an going with new sill to first groove and proper outer sill.

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[sonscar]

I have spent today cutting off the sill and floor.I wish I had not previously made such a good job of a bad repair as it was very difficult to remove the plug welds to deperate the panels.If anyone still thinks oversills are a good idea,think again.Ironically thinking back to my youth it is very possibly because of oversills that so many minis have survived.My experience of MOT welding was:you knew he was doing a poor job and he knew he was doing a poor job but you got your ticket and so tax and you had another 12 months driving.Of course your experience may differ.

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[sonscar]

When I retired I was not going to repair rusty cars again,that did not last long.Cutting out previously repaired patches is very tedious.

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[sonikk4]

The biggest issue with just removing patches is there in invariably more rot hiding.

Personally I bin the whole panel rather than trying to patch in. Not as time consuming. I started do that on my lads car Project Erm and it soon went to full panel replacement every time.

[sonscar]

I understand what you are saying and if I was restoring this car I possibly would replace more.I already have too many cars to look after and I should have moved this one on,but my soft heart made me repair it.It will be a solid sensitive repair as I intend to use it over winter rather than my convertibles.I cut out the patches I previously fitted and will make good with butt welds( hopefully).Thanks for your insight and essential guides.After several MGB restorations working on a Mini is almost relaxing.Steve..

[sonscar]

getting there.childminding today so will have day off.

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[sonscar]

With NEC classic show,wife's car failing mot and water in the garage I have had some time off.Some more.#

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Some more tomorrow hopefully.Steve..

[sonscar]

Oh dear!,looks like this little bit is double skinned and has been previously repaired.Will have a think about what to do,whatever will entail more bodywork than I wanted so I will try to minimise the damage whilst executing a suitable repair.

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I wish I had cut a template of the curve before cutting it off,but there is always the other side?

[sonscar]

Thanks to sonnik and his excellent photos I made a start

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and a repair for the outer panel

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PS wish I had a pressure washer and cleaned the underside before starting.

Edited by sonscar, 17 November 2019 - 10:21 AM.

[sonscar]

quarter panel repaired will primer tonight and fit outer sill tomorrow.

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