Hi Jenko

I'm sure that you'll get the car sorted.....usually you need the outer sill removed or cut an access panel to get at the inner, but with a little lateral thinking you can do the repair without touching the outside sill and thus not having to worry about repainting. This, of course, depends on how badly the area is affected...I had to do some work on mine when it was left sitting on the drive for a few years whilst I rebuilt the engine, a sure way to rust infection. I did cover the repair in detail on my build thread on the PCGB forum but can show a few pictures here.

This shows how much corrosion had occurred...normal place around the torsion bar support, in fact the rust had even eaten into the 1/4" thick plate behind the mount, it's not as bad as it looks as there's a large hole machined in this plate anyway.



rear view...you can just see the top of the access hole that usually has a rubber bung in it..


this picture taken prior to welding... you can see the new 1/4" plate section with it's hole retained and the other galvanised steel sections ready, you need to do these parts first before doing the rear or you won't be able to get a good weld around this area.


the last picture to show the first underseal coat prior to the black coat, you can see the lower drain way in place...I have left off the rubber bung viewing hole as it could lead to more corrosion, plus I have an endoscope for such things anyway. Everything internal was treated to the POR15 ani-rust process which should ensure that no further problems arise, well not in my lifetime at least.



All other areas are very good needing no more than a light brush and under seal in any bare areas. The inside outer sill was replaced about 12 years ago.. the offside is original and still in perfect condition, testimony to how well Porsche protected the 86 model year.

cheers

Pete

Hi, I recently used Precision Porsche (Sheffield Park) to do the timing belts and whilst there I talked to them about the crusty corners on my 944 as they have a Body Shop attached.

I don't want to upset you, but they were quite frank about the costs involved if corrosion is widespread. We were talking about £1000's to do the job properly.

It's not my first rusty classic and these jobs are very labour intensive. Fabricating patches takes time. I've seen on eBay a company that sells Sills, they may also do floorpans.

The only guy I know who has done my cars in the past has stopped doing anything but Jags. I had some welding done by a guy in Hove, near the station. This was only a bit of spot welding. This may be a cheaper option if you use replacement panels.

However, i would recommend going around a few classic specialists and talking about what you need doing. They will be used to this kind of job and give you a frank opinion and quote.



Try to be positive, if you have the work done properly it will add to the value of the car and give you reassurance that you and driving around in a safer car.

Wish me luck for August when my MOT is due.

Andy S.

The news from precision posrche was not good... it needs two new wings and there will definitley be more welding next year for the MOT .... the flloor is solid but there is rust in the other rear suspension mount and a hole in the outer sill near the front wing.
They have put me off tackling it as once the outer sills are removed and the wings off it is likely to cost much more than the car is worth.... have spent a lot on new parts for the car I am in a real fix..... what to do?