Rear sills disappearing due to rust

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andyb2000
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Rear sills disappearing due to rust

Post by andyb2000 » Sun Sep 01, 2019 8:14 am

Hi folks,
Working further on my 480ES 2.0 and just discovered the rear sills pretty much eaten away by rust.

What's the suggestions on repair here, would it be try to strip back and weld new patch in place? If so then it's off to the welders it goes as that's not one I'd be able to do myself.

Just after suggestions and advice really please as this one has me worried over all the other work I've got to do!

Image
Thanks for all your help! - Andy
Volvo480 ES 2.0 petrol - 1994 (UK RHD L-reg)

jifflemon
480 Is my middle name
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Re: Rear sills disappearing due to rust

Post by jifflemon » Sun Sep 01, 2019 8:31 am

Absolutely a job for the welders.

Any corrosion with a 30cm “sphere” of a suspension or seat belt Anchorage is an MOT failure.

You may want to consider attacking it with a wire wheel until you can go back to clean metal, so you’ve a better idea on what’s required

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jamescarruthers
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Re: Rear sills disappearing due to rust

Post by jamescarruthers » Sun Sep 01, 2019 1:36 pm

And the wheel arches? :shock:
1987 Volvo 480 ES, 507274, 217 - Red (Ness)
2001 Volvo C70 2.4T convertible (Olivolvo)
2008 Mini Cooper convertible (Mau)

Previous 480's:
J123 CFU -- ES
J449 MNL -- ES auto
D864 CPV -- ES
L691 JFC -- Turbo
F70 MNR -- ES
H858 FGV -- Turbo auto
E981 KHM -- ES (509849)

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dragonflyjewels
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Re: Rear sills disappearing due to rust

Post by dragonflyjewels » Sun Sep 01, 2019 7:09 pm

Skandix still have repair panels for rear wheel arches, inner and outer, as well as the footboard you have a thumping great hole in. You'll just need a mortgage to pay for it all.....
Sylvia

Snazzy - 1993 Paris Blue ES red dipstick 2.0i bought 2001
Lethal Lily - 1991 White Turbo with richmod
hubby has
Sven - 1994 Dark Green GT
Evil Eva 1992 Paris Blue Turbo with Robou mod

andyb2000
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Re: Rear sills disappearing due to rust

Post by andyb2000 » Sun Sep 01, 2019 7:21 pm

Thanks all, and yes the moneypit seems to be wanting more of my money. I'm determined to get this car MOTd and back on the road, and I can't wait for that day! Long road ahead.
Luckily my brother almost single-handedly re-built a Fiat Uno turbo years ago, that thing was more welds than bodywork in the end, so he's got the MIG welder and the practice so I think he'll be getting called upon.

I'd found the Skandix parts, so I was thinking about:
http://www.skandix.de/en/spare-parts/bo ... t/1046616/
and the right one, hopefully I can then weld these into place and should recover them.

For the wheel arches, I'm unsure. I might be able to do small patches to recover these, so will tackle those separately and hopefully won't need the full wheel arch replacements.
Not ideal, but I'm not going to let this beat me, will document and make photos as I go along, but any advice or adding other supplies/sources for the sills or parts please let me know.
Thanks for all your help! - Andy
Volvo480 ES 2.0 petrol - 1994 (UK RHD L-reg)

Alan 480
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Re: Rear sills disappearing due to rust

Post by Alan 480 » Sun Sep 01, 2019 7:30 pm

£35 for that small section :shock:
its not that difficult a shape to knock up and damn little in the way of 'ill-shaped' curves etc!!!

piece of cornflakes box and sorted, sticking it in will more fun, given the area , but flip side is that it's NOT an overhead weld .. . .
Last edited by Alan 480 on Mon Sep 02, 2019 11:46 am, edited 1 time in total.
Alan

480 ES 2litre x 2, C30 1.8ES, SS1

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dragonflyjewels
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Re: Rear sills disappearing due to rust

Post by dragonflyjewels » Sun Sep 01, 2019 9:07 pm

If it's your bro doing the welding, you can get away with front wings from a breaker for the wheel arches, just need a bit of a tweak. With the amount of visible rust I suspect there's a lot more under the paintwork.
Sylvia

Snazzy - 1993 Paris Blue ES red dipstick 2.0i bought 2001
Lethal Lily - 1991 White Turbo with richmod
hubby has
Sven - 1994 Dark Green GT
Evil Eva 1992 Paris Blue Turbo with Robou mod

arthuy
Can tell where the 480 was built
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Re: Rear sills disappearing due to rust

Post by arthuy » Fri Sep 06, 2019 9:37 pm

Recent experience, If you hit it with a wire brush it will be worse.
The thick rubber underseal hides alot. Rust comes from the inside.

You can see the inside if the arches if you take the boot trim off.

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