Rotting Inner Sills - Graphic Content Inside

[BongoMTBer]

Not for the feint hearted - look what I uncovered today.

Anyone had similar repaired?

She is booked in for a couple of weeks time whilst I get the rear arches done too.

LH side, just aft of cross-member.


LH side, just below sliding door well.


RH side, just aft of cross-member.


RH side, around rear heater unit.


Just fwd of RH rear arch.


Just fwd of RH rear arch.


It's the last two pictures that worry me most as there the whole area seems to be rust. Would probably be worth a new inner and outer sill there, but not really sure if it is worth spending the money.

Any opinions?

[bigdaddycain]

It looks as though there are a few repair patches underneath some of that corrosion too... had it been waxoyled at all in the past do you happen to know?

[BongoMTBer]

I got it chassis-cleaned a couple of years back, but the rot had already started. At least the rest of the van is ok (apart from rear arches). I don't think it has been patched before though, the layers are overlaps from original from what I could work out. I would love to cut it all out and have new pieces put in but not sure what that is likely to cost.

I love mechanincal, but hate bodywork with a passion!

[al & chris]

Do you think having it chassis-cleaned slowed the rot down. We were thinking of having ours done, showing signs of light rust on rear arches.

[bigdaddycain]

Just forward of the RH @ LH rear arches look really nasty, and to me look the trickiest to repair (from a good metal to weld to point of view)

[BongoMTBer]

Do you think having it chassis-cleaned slowed the rot down. We were thinking of having ours done, showing signs of light rust on rear arches.

Yes it probably has but more importantly, it has kept the bits that are good - good! I would get the rerpairs done ASAP then chassis cleaned - before winter.

[bigdaddycain]

I have to ask... Why did chassis clean take the job on when some of the floorpan was already compromised? Surely it would have been cheaper (with hindsight) for them to patch the smaller holes then? Hell...They could have cut out big rotted sections, then squirted waxoyl right along the inner cills whilst they had the access, then weld the holes back up and do their thing on the rest of the floorpan... You wouldn't have been looking at those holes now, if the job had been done right back then!

[BongoMTBer]

Just forward of the RH @ LH rear arches look really nasty, and to me look the trickiest to repair (from a good metal to weld to point of view)

I think you are right, especially on the RH side.

[BongoMTBer]

I have to ask... Why did chassis clean take the job on when some of the floorpan was already compromised? Surely it would have been cheaper (with hindsight) for them to patch the smaller holes then? Hell...They could have cut out big rotted sections, then squirted waxoyl right along the inner cills whilst they had the access, then weld the holes back up and do their thing on the rest of the floorpan... You wouldn't have been looking at those holes now, if the job had been done right back then!

No comment! A heads up on the problems before they stuck rubber patches over them to trap the moisture would have been nice too. Also, not bolcking the drain holes would have been useful.

[bigdaddycain]

Aw man! And we aint experts! And we'd know not to do that!

[bigdaddycain]

It's really sad to see... My bongo's tax is up in a few days time... I'll SORN her till April or May 2012... Not a wheel will turn on a salted/gritted road. Yes i do only have a "cheapo" waxoyl job done each year, but it seems to be working... Bongo's are not protected in the factory to cope with gritted roads...they were never intended to cope with out harsh road gritting, the japanese don't grit their roads... It's the grit that kills our beloved bongo's!

[BongoMTBer]

Now I know my way around a Bongo, I would wayoyl myself if I got another. I always have some on standby for when I remove bits - its great stuff and works a treat.

[bigdaddycain]

Are you going to get her repaired?

[bigdaddycain]

Worded correctly... It might just be worth returning the bongo to chassis clean and let them have a look... Drop hints about how much to get repaired there, by them... If you don't like the quote, suggest it might not have happened at all if the offer of patching the floorpan back then had been pointed out/offered, then ask for another quote with a cheeky smile...

[BongoMTBer]

Won't be going back there. Not even sure they do bodywork???

I am taking it to Ian Taylor who always seems to come up with the goods. I just want to get it sorted.