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Internal Sill repair

This is the section to see what is hidding behind those panels, and how to get rid of the tin worm, cutting out and welding in fresh metal, protection and paint.
The-mx5-restorer
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Internal Sill repair

Postby The-mx5-restorer » Sun Mar 09, 2014 8:13 pm

These pictures will give you a good idea of what the internal structure of the Sill is on the Mk1 MX5, the MX2 is very similar, they will also show you how a correct repair should be carried out

This car didn't actually look that bad before we cut it open, and even with our experience we didn't expect to find this inside

Image

Image

Image

Image

now the best way to tackle any rust repair is not to look at the rusty holes wondering how you are going to deal with them, its best to simply cut it all out things always look more simple and easier to deal with then

Image

Image

see how that looks much less scary now

now you can concentrate on making bits of metal to repair the holes left

Image

When things are this bad we then use a rear section of sill

Image

Image

and there it is, a full internal sill repair, after this the outer panel can go on, I forgot to take pictures of this one with the outer panel on, but you get the idea from these pictures of another car we did recently

Image

Image
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Mazda Mender
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Re: Internal Sill repair

Postby Mazda Mender » Sun Mar 09, 2014 8:21 pm

Mmmmmm crunchy bits, :text-goodpost: :text-coolphotos: :bow-yellow: :handgestures-thumbup: :coffee:
M-m
The Disclaimer:-
This post is a natural product made from recycled electrons. The slight variations in spelling and grammar enhance its individual character and beauty and in no way are to be considered flaws or defects, the articles/answers/comments are provided for information purposes and they are not intended to substitute informed professional advice, I or mazdamenders.net cannot personally be hold responsible for any damage occurred from following this procedure or any injuries from it. Proceed at your own risk.


Mk 1 Eunos 93 black V.S II 1.8 ,
Mk 2 .1/4 Roadster 99 black & gold V.S 1.8 being rebuilt,
Mk 1 Eunos 90 1.6 (claimed by daughter)
MK 2.1/4 Blue V.S Roadster 1.8 99 ...being rebuilt

http://www.mx5oc.co.uk/ http://www.mx5nutz.com/forum/ http://miata.net/ http://www.autolinkuk.co.uk/
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mk1divemaster
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Re: Internal Sill repair

Postby mk1divemaster » Sun Mar 09, 2014 11:29 pm

Not so easy for a layman !! Lol
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cjgreaves41
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Re: Internal Sill repair

Postby cjgreaves41 » Sat Jan 07, 2017 9:24 pm

I know I'm bringing this back from the dead but excellent pictures! Helping no end with what I'm trying to do. Does anyone have any picture of the sill/ wing once the new wing has been fitted? How was it originally fixed to the putter sill? Cheera
John&Luke
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Re: Internal Sill repair

Postby John&Luke » Tue Jan 10, 2017 11:01 pm

cjgreaves41 wrote:I know I'm bringing this back from the dead but excellent pictures! Helping no end with what I'm trying to do. Does anyone have any picture of the sill/ wing once the new wing has been fitted? How was it originally fixed to the putter sill? Cheera


Hi I'm no expert having only so far replaced one of my rear wings but this may help.

So I noticed that the new wing I purchased just ended without a 'return' flange which didn't seem right to me. I therefore decided that the wing needed a 'return flange' so that I could spot weld it to inner sill return flange. I've trying to draw this on in the next picture and also shown the additional section.
Image

I've shown the inner sill return flange below.
Image

So I added a new section to the bottom of wing so that I could then spot the wing to the inner return flange as shown below. I also added a drainage weep vent so that any water that collects behind the wing can drain. I've drawn a cross section on this set up on the photo to try to explain a bit further.
Image

Hope this helps.
1996 Mk1 Classic Red 1.6 sorted
1995 Mk 1 White 1.6 in need of TLC
2015 Mk1 1.8 Exocet Mk1 on steroids
John&Luke
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Re: Internal Sill repair

Postby John&Luke » Tue Jan 17, 2017 10:16 pm

Hi,

Just an update to make my last post a bit clearer. Photo of the bottom of a new rear wing with 'MY' bottom return flange solution fitted.

Nice finished job in my opinion. :-D
Image
1996 Mk1 Classic Red 1.6 sorted
1995 Mk 1 White 1.6 in need of TLC
2015 Mk1 1.8 Exocet Mk1 on steroids
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Brgdane
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Re: Internal Sill repair

Postby Brgdane » Thu Jan 19, 2017 9:17 am

Nice and clean solution


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cjgreaves41
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Re: Internal Sill repair

Postby cjgreaves41 » Wed Apr 12, 2017 9:54 am

John&Luke Really useful post! I'm half way through doing one side of mine! Scar but getting there! Picture are helpful!

Cheers
John&Luke
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Re: Internal Sill repair

Postby John&Luke » Mon Apr 17, 2017 3:45 pm

cjgreaves41 wrote:John&Luke Really useful post! I'm half way through doing one side of mine! Scar but getting there! Picture are helpful!

Cheers


Couple more photos of the process I followed.
Old outer wing cut awat and inner wing repaired and painted with weld through primer.
Image

Trial fit of replacement wing.
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Tacked into position
Image

Fully welded
Image

Filler applied, rubbed down with 80 and then 120 grit, then guide coated before primer
Image

Primed and flatted back with 320 grit
Image
1996 Mk1 Classic Red 1.6 sorted
1995 Mk 1 White 1.6 in need of TLC
2015 Mk1 1.8 Exocet Mk1 on steroids
drumtochty
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Re: Internal Sill repair

Postby drumtochty » Tue Apr 25, 2017 12:27 pm

Good work that man!!!!!!!!!!!!!!!!!!!!!!!!!!!
1999 Mk2 Silver
2008 Mk3 Copper Red
Drumtochty Glen, Auchenblae, Aberdeenshire
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storm
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Re: Internal Sill repair

Postby storm » Tue Apr 25, 2017 3:23 pm

The-mx5-restorer wrote:These pictures will give you a good idea of what the internal structure of the Sill is on the Mk1 MX5, the MX2 is very similar, they will also show you how a correct repair should be carried out

This car didn't actually look that bad before we cut it open, and even with our experience we didn't expect to find this inside

Image



And this is why i sent my car to you straight away. What a basket case it was. I sent a few people your way at the spring rally as they were asking about the bodywork done to my car. :handgestures-thumbup:
1. A car is only worth what someone is willing to pay for it, 2. Resale wont save your life in an accident, 3. Genius has limits, stupidity has none, 4. Never argue with an idiot, they will bring you down to their level & beat you with experience, 5. Growing old beats the alternative -- dying young!
SmokeJaguar
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Re: Internal Sill repair

Postby SmokeJaguar » Sat May 05, 2018 12:57 pm

Hmm would like to follow this thread but no pictures are showing
drumtochty
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Re: Internal Sill repair

Postby drumtochty » Sat May 05, 2018 3:31 pm

Nothing new here, the photo issue started in summer 2017 when the photo hosting site Photobucket tried to hold users to Ransom.

If you use either Google Chrome or Firefox as a browser search for the photobucket fix that gets over this.

Not sure what other browsers have the fix available.
1999 Mk2 Silver
2008 Mk3 Copper Red
Drumtochty Glen, Auchenblae, Aberdeenshire
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Mazda Mender
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Re: Internal Sill repair

Postby Mazda Mender » Sun May 06, 2018 9:00 am

It took months (and there are still some ?) to down load all the pics i did and re add them...lucking for us we can drag and drop or attach pics from any device straight to the board which means we do not need a third party to host them ...they self size and once locked in are in for good on our back ups...clicking on lockied in images on here expands them for better veiwing ,un fortunately we cannot do anything about other members post with them missing unless they re add them for the greater good or send them to us to re add...
Eddy...
If you can see them can you save them and send them direct to me buddy as you find any and i'll re add them were needed..
M-m
The Disclaimer:-
This post is a natural product made from recycled electrons. The slight variations in spelling and grammar enhance its individual character and beauty and in no way are to be considered flaws or defects, the articles/answers/comments are provided for information purposes and they are not intended to substitute informed professional advice, I or mazdamenders.net cannot personally be hold responsible for any damage occurred from following this procedure or any injuries from it. Proceed at your own risk.


Mk 1 Eunos 93 black V.S II 1.8 ,
Mk 2 .1/4 Roadster 99 black & gold V.S 1.8 being rebuilt,
Mk 1 Eunos 90 1.6 (claimed by daughter)
MK 2.1/4 Blue V.S Roadster 1.8 99 ...being rebuilt

http://www.mx5oc.co.uk/ http://www.mx5nutz.com/forum/ http://miata.net/ http://www.autolinkuk.co.uk/
SmokeJaguar
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Re: Internal Sill repair (Photobucket Issue)

Postby SmokeJaguar » Sun May 06, 2018 7:45 pm

Ahh my apologies i was ignorant of this issue, yep using Chrome the photos show up.
Cheers.

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