Mk1 Berkeley - Time for a new outer sill section?

Technical Area Body, Interior & Styling
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Folks,

While bleeding the rear brakes I decided to check around the sills with an inspection lamp. I had injected the sills a couple of years ago with Dinitrol and removed some light bubbling to the sills and zinc primed them and sprayed with stone chip guard. Upon inspection, I notice some bubbling again so decided to take the paint back to take a closer look. See below, I made the hole having a really good poke around, well I say hole, but it has not gone all the way through and is pretty solid underneath, although rusty. I also noticed some rust at the inside bottom of the wheel arch. The rest of the car is solid.

Can this be patched up again and then go for a sill replacement in a couple of years, or is it better to just get it done now? It does’nt seem that bad to me, I’ve seen allot worse, but I guess it is what lies beneath! Expert opinion appreciated before I decide what to do. Thanks.

Paint removed.

The hole, not completely holed yet!!

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That hole is all the way through the outer wing. What you can see is the sill strengthening member. As it stands, thats an MOT failure. Where its gone is just the tip of the iceberg. To get to solid metal will need a lot more cut out. its rusting from the inside out in multiple places.

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I came across one spot of rust on the lower rear section of one sill a couple of months ago. Like you I’d previously had a look inside the sill sections (which were spotless) and  treated with waxoil, so was a bit disappointed, but really expected it one day after everything I’ve read and seen on here.

I investigated the rust spot, and like you found a small hole in the outer sill panel.  I cut a small window in the panel to have a proper look, and found surface rust on the face of the inner sill, and back surface of the our sill.  I then cut a sightly wider section out, and came to a point were the inner sill was no longer rusty, but there was still a film of surface rust on the back of the outer sill panel.

I cleaned up the exposed inner sill, and treated with rust killer.  I also injected rust killer, then waxoil as far as I could get it in every direction around to area I’d cut out, in between the inned and outer panels.  Lower down on the bottom curve there is actually a small gap between the two so it is possible flood that area. I jacked the front of the car up and warmed the sill with a heater so that the waxoil would run along the length of the panel.

A friend who is currently doing up a midget and into welding, welded a small patch over the repair, which I’m in the process of sorting best I can cosmetically.

I’m under no illusion that there will be some degree of surface rust or maybe worse elsewhere behind the ‘perfect looking’ rear sill panels, and am planning to have both sides fully and professionally replaced some time soon, maybe this autumn time.

I have considered drilling a few small holes through the rear outer sill panel further along, and on the other side to flood the rest of the void between inner and outer panels with rust killer then waxoil to hopefully hold things off until I get down to major surgery.

I love Mk1s and have been really tempted by some very low mileage ‘minters’ that I’ve seen for sale over the years, but would be very guarded at paying a premium price for a totally rust free one , as there is no way of knowing what is going on in the thin void between these two sill panels - until the first rust bubble appears that is!

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I had a similar sized hole on my 1996 Roadster, which I had arranged to be repaired while the car was being repainted. The repair used was a patch over the hole, as I found out. 18 months or so later, it looked a mess. The patch might have made things worse.

You can just about see the patch. Not sure if the patch accelerated the rot, because it created a moisture trap, or really, that little hole was just a harbinger of doom, and the whole lot needed to be chopped out. Certainly the delay mean more repairs to the wing lip; if it had been done properly 18 months earlier, possibly the original lip could have been retained.

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 AT, I accept and agree with what you say.  The patch on mine is only about 4" long, as beyond that the inner sill seemed rust free, but obviously no idea what happens beyond that.  I dealt with the rust directly behind the patch as well as any garage would do, and injected converter and wax oil beyond.

As said, I’m under no illusion of what the inevitable will be, and plan to deal with it fully as soon as time and funds allow.  Ray

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Thanks for all the advice.

Booked  in with Carl at CBS decide to get both sides done, even though the off side has no signs yet! Its a bit of a trek up to Lanc’s, but want the job done properly.

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Nice-one Dan! It might be a trek, but at least its to Luvly Lancs, and you’ll be guaranteed the best possible job on your Berkeley sills.

I’m booked in with Carl for a few mechanicals  in a couple of weeks time, before our trek further north for the Spring Rally, and planning to get my sills done later this year.  Let us know how you get on with yours.

I bought your chrome mirrors - it’s a bit back - still in box - who knows might get round to fitting them this year! 

 

 

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It was CBS who did the work on my car and I’m vary happy with the results. I’m sure you will be as well.

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Dropped my Berkeley off with Carl this morning to have both sills seen to. Off side one looks OK, but worth cutting back and checking and treating. Will end up being a 300 mile round trip for me. But I wanted it done properly and going by the reviews and meeting Carl, he has my full confidence that he will do a first class job. He is a perfectionist and it was nice to meet a like minded soul.

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When do you get it back Dan.  I’ll be interested in what is found, and the resulting job (which I’m sure will be perfect). Ray

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Hi Ray,

It will probably be with him for just over a week or so. He said he would send me some pictures through of the inners so I’ll post them up when I have them.

Dan

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 Thanks Dan. I look forward to the photos. Mine might be next. Ray

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Heres some photos as promised. If your looking to buy a UK Mk1 expect some rot to the rear outer and inner sills. I dont expect an import to be much better if it has been on UK roads for 4 years or more. Allow £550 to get the sills done properly, not just a temporary plate over job which just hides the problem. My Mk1 has only doen 38K and has been garaged so dont pay over the odds for something low mileage!

As you can see from these pictures, Carl at CBS Autos does a proper job. I’m yet to see the finished work as I haven’t picked the car up yet. But based on meeting him, and these pictures of his work, I cannot reccommend him highly enough.

You can see some of the dinitrol I injected in the past, just visable through the hole in the inner sill. The problem is getting the cavity wax between the inner and outer sill mating faces.

OSR was showing no signs of rust on the outside, but decided to get it done anyway, glad I did!!

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Thanks for sharing the photos Dan. As you say, there would be no telling what lay beneath the cover sill, no matter how perfect things look on the outside - perhaps there is no such thing as an original rust free Mk1.

Mines in with Carl next week having the cam belt and water pump done and a few things checked over before our two weeks in Scotland.  I’ll be planning a sill visit later in the year.   

Look forward to seeing the finished result. Ray

 

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Oh there are…they just have never been driven in the UK!

You have to feel sorry for car makers that want to sell cars in a country that coats the roads in SALT for half the year. It’s hardly their fault that metal rusts here…it’s frankly a bloody stupid idea.

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Carl at CBS Autos Nelson BB9 7BJ, great choice, you will definitely get a very thorough job done.  I had the offside sills"Carled" on my wife’s red Arizona &

my Laguna Blue 1.8 S Special, excellent work.   I’m based just 37 miles from Nelson & it’s a great drive.  Carl supercharged my Splash Green MK2.5, well pleased.

All things MX5 contact carl@mx5specialists.com you will not be disappointed.

Keith