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Hi all, how much pitting can you accept before replacing? The worst of my inner sill is bottom front and on the top lip at the back. My initial thoughts are to replace the top section but that the bottom front is ok. I can't poke anymore holes in it.

Cheers
Dave

I would try and get in behind to clean up and hold some copper or ally then spot fill with mig. Grind flush, good as new. As long as you can stop further rust, that’s the main thing. It’s probably going to be garaged and not driven in the rain. Make it look tidy and protect it with non porous coating such as two pac primer, por 15 or metalfix like I’m using.


FB ute fixer upper, EK van on rotisserie

Errol62 wrote: Mon Jul 08, 2019 8:53 pm I would try and get in behind to clean up and hold some copper or ally then spot fill with mig. Grind flush, good as new. As long as you can stop further rust, that’s the main thing. It’s probably going to be garaged and not driven in the rain. Make it look tidy and protect it with non porous coating such as two pac primer, por 15 or metalfix like I’m using.


FB ute fixer upper, EK van on rotisserie

You mean fill the pits with weld? I'm glad I asked, I never would have thought of that.

Thanks Errol

Dave

Good luck with it. It’s taken me a while to get the technique right, but if you can get the metal clean, get a heat sink hard against the back of the hole and get the heat just right. Aiming the wire about 30 degrees to the surface a little outside the hole to build up metal and then work back in to the hole. Sometimes it becomes apparent the piece is too badly pitted. It can still be done but works out less work and a better finish to put in a patch.


FB ute fixer upper, EK van on rotisserie