"It doesn't look too bad at the rear, I'll just replace this repair panel whilst I'm here and the fuel tank is out"

 

More of an informative post but this looks like what can happen when you repair the rear sills without extending/replacing the targa roof drain. These were welded in 2011, and the car has done 1000 miles since then before my purchase as a project.

 

Anyone else experienced this and have any advice?

 

Was thinking of cutting a peep hole into the new metal I use for future purposes, such as with the front sills, thoughts?

 

So I saw this panel, small hole near the subframe supports, cut it off..

 

 

Camera inside it:

 

 

Could rip the metal apart with my fingers

 

 

Outer panel off

 

 

 

And the suspected culprit

 

Ouch! I'd cry!

 

I've seen inside my sills with a boroscope and there's zero rust thankfully.

the frightening thing is my passenger side sills are probably just like that :headvswal

I also have a UK car and had very similar corrosion! (I did cry to begin with)

But after some serious thought, I decided to try and save her.

 

Here's my diary of events...

 

http://www.mig-welding.co.uk/forum/threads/thanks-everyone.15465/

 

Bit of a read, but may be of some inspiration.

The targa drain strikes again :sad:

Ah I've read your post over many times redwine, exact same issues, floor panels etc all needing done too. Your welding has inspired me haha

Im also on the rust trail expecially after welding before, im sure for some reason that once the steel gets heated after welding its more prone to corrosion

 

my rear inner wings were shot but im managing slowly to repair them, I had a look in my sills and yep they look like yours so that the next job

again mine were previously repaired but also the drain had been extended passed the sill and out, so cant blame the targa drain

I coated the inside with aquasteel to be sure it wouldn't rust again but to my surprise its gone again, I asked aquasteel to comment on this and in the small print it says recoat every 2 years ffs

 

deffo be using waxoil this time and zinc rich primer in the sills as I have done with the rear arches

 

I have trouble with mine as the side skirts are fiberglass and blended in so I have no access the the sills without cutting them off and trying to put them back somehow

 

mine also a uk spec 1990

when i got the drivers side sills/arch done my friend put an little access plug/cover so u can insert a spray wand then just redo the inside of the sills

Im also on the rust trail expecially after welding before, im sure for some reason that once the steel gets heated after welding its more prone to corrosion

 

my rear inner wings were shot but im managing slowly to repair them, I had a look in my sills and yep they look like yours so that the next job

again mine were previously repaired but also the drain had been extended passed the sill and out, so cant blame the targa drain

I coated the inside with aquasteel to be sure it wouldn't rust again but to my surprise its gone again, I asked aquasteel to comment on this and in the small print it says recoat every 2 years ffs

 

deffo be using waxoil this time and zinc rich primer in the sills as I have done with the rear arches

 

I have trouble with mine as the side skirts are fiberglass and blended in so I have no access the the sills without cutting them off and trying to put them back somehow

 

mine also a uk spec 1990

 

Cut the skirts off and keep them off. :)

Sounds very appealing for leaving a grommet' hole then for spraying in more underseal.

 

Taken it back past the rear sill quarter panel, considering just doing the whole side

 

This is it ready to weld (hah jk). Still a good bit of cutting to do. It's crept right into the jack support (and i have since removed my axle stand from that area..), luckily the ~3mm steel is still solid.

 

Going to clean it up nice and shiny, take it back further if need be, and weld additional plates on before going onto the standard plates so I'm confident in the strength.

 

Have you guys welded additional panels in this manner too? Or will this cause moisture trap and future corrosion?

 

 

Take a look here, there are various treatments and coatings available.

http://www.bilthamber.com/

 

May be of interest.

Going okay, only 3 more panels to go! Floor required further cutting than i thought. Fabricating that corner.. jesus.

 

Any advice on the targa roof drain replacement? Would simple garden hose work?

With a car that's prone to rust it's really good to see some people getting stuck in. In reality virtually all these cars will suffer from tin worm eventually and it's only the progression of the owners and their willingness/capability to repair that will keep them from the scrap. I'm fully aware at some stage il need to get serious on the chassis on mine, currently it's ok but it's only a matter of time.