Dreaded sill rust >.<

Hey all

 

After selling my NC a couple of months back and buying an E89 Z4, I’ve wanted to get myself an older NA for the odd bit of fun here and there.

I bought a Eunos Roadster a couple of weeks back, it had some lighter mods which I’m culling and returning to stock along with fixing any issues. The machine is far from perfect, a bit of a turbulent history but I’m willing to put the hours and notes in to making it 1st class again.

Anyway I bought it with what looked like a small amount of surface rust on the arches/sill and wanted to tackle it myself. Like you do, I poked and prodded and low and behold it was rotten to the core and filled with filler. I’ve not checked the passenger side in depth but it’s almost guaranteed to be similar. I already put money aside before the purchase to have this type of work done, I’ve got it booked in for a check at the local MX5 specialists but I’m wondering if anyone could give me a ‘guide’ as to how much this type of work might set me back. 

I’m thinking I want the sill completely restored back to front, rear arches and front wings sorted/resprayed too.

Any ideas or advice is much appreciated, thanks in advance :smiley:

 

driver side sill

driver side front wing

http://www.ultraimg.com/image/G1e4

 

Hi…Not sure if the link above will get you to my photos of the work done.   Oooops!   Bingo! done it!  Did some more fiddling - see below for a selection.

Rear NEARSIDE sill rusted out - cost for rebuild (inner and outer sill sections)…paintwork +treating the offside rear sill surface rust and  then all four rear wheel arches was £400.   I was happy with the results but no doubt there are others who might better this cost.   I could never have done a DIY job on it!   The work was done by a couple of local guys, one the welding repair specialist and the other the paintwork.  Others may think that this was expensive but I was very pleased with the results - as good as new if not better?

 Hope this helps.

 

Ooops! Made a mistake …forgot that the metalwork was another £160.

 

changed the above from offside to nearside as any observant individual would have noticed from the photos!    It’s that age thing again!!!

OK it is not a Mk2 so probably no front chassis rails and depends on if you want a two year patch or sorted once and for all.

To do it correctly you would want assuming rust all round.

Two new front wings.
Two rear wings
Two major inner sill repairs at the rear.
Some patching to the back of the front wheel arches maybe.
Some patching to the floor and maybe the boot floor.
Pleny rustroofing afterwards.
It is probable that if all this needs done you may as well do a respray.

Therefore worst case front wings say £500 fitted and wheel arches welded, rear end say £1,200 to £1,500 fitted, paiting say £1,500 and rustproofing say £150.

Total £3,600 but call me too “worst case” therefore putting in some better news I would say £1,800 to £4,000 depending on what is wrong and what you are prepaired to pay for.

Best case is you get two clean and painted front wings the same colour as your car from a scrapper and no front arch damage say £250 fitted, no floor or boot rust and little inner sill repair work. In that case the total cost of the rear end work and sparaying is say £1,500. Therefore total cost is £1,800. I guess the final cost will be somewhere between the two numbers.

 

OK it is not a Mk2 so probably no front chassis rails problem and depends on if you want a two year patch or sorted once and for all.

To do it correctly you would want assuming rust all round.

Two new front wings.
Two rear wings
Two major inner sill repairs at the rear.
Some patching to the back of the front wheel arches maybe.
Some patching to the floor and maybe the boot floor.
Pleny rustroofing afterwards.
It is probable that if all this needs done you may as well do a respray.

Therefore worst case front wings say £500 fitted and wheel arches welded, rear end say £1,200 to £1,500 fitted, painting say £1,500 and rustproofing say £150.

Total £3,600 but call me too “worst case” therefore putting in some better news I would say £1,800 to £4,000 depending on what is wrong and what you are prepaired to pay for.

Best case is you get two clean and painted front wings, the same colour as your car from a scrapper and no front arch damage say £250 fitted, no floor or boot rust and little inner sill repair work. In that case the total cost of the rear end work and sparaying is say £1,500. Therefore total cost is £1,800. I guess the final cost will be somewhere between the two numbers.

 

 

Thanks for the input people.

 

@Ralf - That sounds like a great price for all the work you had done, does it look as if it’s long lasting?

 

I’m willing to pay a good chunk more to have them permanently done along the entire sill as opposed to just the rear segments. I’ll see what the diagnoses is this weekend.

My 96 is in for arches and sills, both sides, which with the internal patch ups, will come to about £600 a side, by Thrussington Garage, east Goscote. There is some other paint work being done at the same time, so I may get a bit of a discount on the painting. Paintwork will be done by the shop that normally paints their MX5 race cars.

 

About halfway done.

 

Drivers side, all original

 

 

Passenger side; there is an older repair I had done in 2009, which was starting to bubble, but the arch (original) was starting to look a bit uneven. despite it amountin t little more than a patch and filler, its held up well.

 

 

Drivers side, with new part panel tacked on. A lot of repairs were needed to the sill

 

 

Passenger side; what seemed to be a solid arch, when cut away, was not, and the inner wing lip had to be rebuilt. Surprisingly, the sill member under the old repair wasn’t too bad, with just a small repair needed.

 

 

If you are thinking of keeping the car, I would factor in an arch repair as well. My 93 S-Limited Roadster, despite copious dinitrol in the cavities, is rotting  in the sills as well, and potentially, even worse up on the quarter panel (away from the lip); I think this is related to a body repair carried out by the importer when it was originally brought in.

Every time I see these types of post I thank myself I was very lucky!

 

Bought my MK2 naively Nov 2015 and didn’t know about the rust issues with sills & arches - but mine are fine - no rust & no issues.

 

Then again whoever had my car originally had it in Jersey for about 10-12 years doing hardly any mileage - very few roads out there & I don’t think they put salt & grit on the roads. Only now just hit 63.5k miles a well, not bad for a 17year old car!

Low mileage decent rust free ones are out there - I admit I was very lucky

As always there are some clean cars out there. Even here in North East Scotland where a lot of road salt is used, I know one Mk2.5 that is still rust free and lots of others that are typical Scottish rusty cars.

Happy you have a clean car.

If you’re anywhere south of the M4, it would definitely be worth giving Paul on 07947 632976 a call.
He recently repaired/painted both rear sills on my Mk1 to a very good standard, very quickly, and at a sensible price.
He’s based near Bishops Waltham in Hampshire.

Tikkapete