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Car Forum / MINI / February 2004

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replacing sills

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courtlandkevin - 23 Feb 2004 22:39 GMT
How dificult is it to replace the outer sills on a late mini (93)? The
sills on my mini are showing rust around the spot welds in the bottom
edges and at the fronts. I've been told it is important to keep on top
of this as they can rot quite quickly from the inside if left. What
sort of price should I expect to pay to have the new sills welded if I
remove the old ones and clean up the metal on the inner sills.

Thanks
kevin
Jono Barspeed - 24 Feb 2004 00:11 GMT
I was told that the sill work and arches could top ?800!
I traded it in for a new classic..............
The work is very involved and worth doing properly, so when redoing the
sills, the old ones are removed completely exposing the inside of the inner
sill and inside of the door step and lip, once all the crap is ground off to
clean metal, only then can you fit the standard fitment sill, not a wide
sill, this is a cover sill for botch jobs, you need a narrow sill which is
the one you need just to fill the gap!
When welding on the sill, start by tacking it on with spot welds about
4inches apart. When the sill is attached well all the way around, start
filling in the gaps between each spot, then stop and allow the metal work to
cool each time, this prevents warping and the metal bending and hence
popping the spot welds off! You dont have to do this really, because a
replacement sill doesnt need welding all the way around, but I would never
do that, this is structural after all!
When welding on a sill at the bottom of the quarter panel, cover the paint
work with lots of exhaust paste, this will protect it from welding sparks
and flashes, it should stop the paint bubbling as well, not perfect but it
helps.
At the rear of the sill, make sure that sill is welded well to the footplate
beneath the rear seats and also round into the front wheelarches.

jono

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> How dificult is it to replace the outer sills on a late mini (93)? The
> sills on my mini are showing rust around the spot welds in the bottom
[quoted text clipped - 5 lines]
> Thanks
> kevin

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