Sills....

[andyg plym]

Ok so I have a problem with the o/s sill from where it has been jacked up over the years,
the front part closest to the wheel has folded under itself

what is best to do? its not like I can bend it back surely? Its very thick metal.

Anyone else had this?

Could it be beaten back,welded for strength then hammerited over?

thanks for any help offered

[Monkeymagic]

You can sort of straighten the seam where inner and outer meet. then treat it. then apply black stone chip from an airline you'd hardly notice once done.

[Error404]

Ok so I have a problem with the o/s sill from where it has been jacked up over the years,
the front part closest to the wheel has folded under itself

what is best to do? its not like I can bend it back surely? Its very thick metal.

Anyone else had this?

Could it be beaten back,welded for strength then hammerited over?

thanks for any help offered

Hey andy,

A problem I know all too well. both my sills were fooked like this on my coupe - one i cut the damaged section out, the other I had done by a body shop, but its just aq quick fix (basically they plated over it)
I have one repalcement sill, I need the other one. One day once everything else is done on the car I will replace both sills complete - but I am mr a-n-a-l.

You could weld to it and use a slide hammer or a hydraulic puller to get it roughly straight then use a light skim of filler

[shaun5]

You could weld to it and use a slide hammer or a hydraulic puller to get it roughly straight then use a light skim of filler [/QUOTE]

The above would be my suggestion.

I have got a 80 saloon that you can cut the sills from if you want andy

[Monkeymagic]

ive got a slide hammer and porta pack you could use but bit of a distance.

[re2500]

I had a similar issue on a MK3 (but it had lead to some nasty rust eventually)
I would suggest that in order to get max strength back (otherwise it may just bend again when you jack it) get a decent bodyshop/welding guy to cut the offending section out and fab and weld in some new pieces with a decent gauge of steel. I got a really good guy to do my mk3 for about £80-100 (hes spent most of a day on it in the end, but he's pretty OCD!)
Just make sure he puts a good bit in the middle for strength (the original sill has an outer skin and inner skin and a vertical piece for strength when jacking, all three are joined at the offending seam )

[bluequattro]

Cut it out, add a short piece of vertical box section, then 3 mm plate it, won't bend then!
I ve used 3mm on a pillars on gts when rusted/sagged

[Monkeymagic]

personally when i work on my cars or anyone elses i always use the rubber boot on my jack and where ever possible jack on subframe mounting point so not to break underseal of bend anything. Im convince lots of this kind of damage is done by tyre fitters.

[TimE-J]

I've got the same problem on both of my sills at the front. really annoying as when looking at the side of the car you can see both sills have been jacked up and bent at the front!

[Mcstiff]

My plan is to cover the sills with shortened B5S4 plastic.

[bluequattro]

2 post lift finished off our sharans sills at the front
I only jack on cross members if possible- I have to drive the quattro onto small wood blocks first as the jack won't go under!
The urs4 was other way around- jack was hardly tall enough to get axle stands high enough!
Needs lowering a bit!

[Greg_S]

I had same issue on mine, wire brushed down.

Treated with Flag rust converter
2 Coast of POR15
Coat of seam sealer
Cost of underbody sealant