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  • #16
    I replaced ours because I had access to a rust free scrapper. I could have made a repair panel as it was just the front lip really. I have kept the one I cut out as I was toying with having a go at making a couple if I can get the time as I have a metal folder. And the cross section though the old one shows how to fold it. Your doing a great job.

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    • #17
      Was there any expanding foam type stuff in your sill about half way down the door?

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      • #18
        U don't fuck about. Good job mate [emoji106]

        Sent from my SM-G930F using Just T4s

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        • #19
          Well done , nice too see your doing a good job , I wish I had a big enough garage to put my van in so that I could crack on with jobs.

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          • #20
            Nice thread, keep it coming.
            Me cago en la madre que te pariĆ³!

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            • #21
              Originally posted by S49 View Post
              Was there any expanding foam type stuff in your sill about half way down the door?
              Yes right in the centre of the step, when I started cutting the step out and saw it I thought what Muppet does repairs like that. I then realised it was factory! Don't know why VW added this as they already added a double brace type support there. Maybe wanted the steps to rust out a bit faster[emoji38]

              Sent from my SM-G930F using Just T4s

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              • #22
                Originally posted by Hans View Post
                U don't fuck about. Good job mate [emoji106]

                Sent from my SM-G930F using Just T4s
                I'm trying mate, lucky I've had a few days off work so getting as much done as possible to assess the extent of the rot...the jury is still out!

                Sent from my SM-G930F using Just T4s

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                • #23
                  Originally posted by Jonny888 View Post
                  Yes right in the centre of the step, when I started cutting the step out and saw it I thought what Muppet does repairs like that. I then realised it was factory! Don't know why VW added this as they already added a double brace type support there. Maybe wanted the steps to rust out a bit faster[emoji38]

                  Sent from my SM-G930F using Just T4s
                  I have heard vw doing things like this before, b5.5 passat arches rotted out within 3 years b3couse of a similar design floor.

                  Sent from my SM-G960F using Just T4s

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                  • #24
                    Originally posted by Greeny gtc View Post
                    I have heard vw doing things like this before, b5.5 passat arches rotted out within 3 years b3couse of a similar design floor.

                    Sent from my SM-G960F using Just T4s
                    You're right mate, VW etc spend millions on R&D and yet they slip some really stupid ideas into the mix.

                    Sent from my SM-G930F using Just T4s

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                    • #25
                      I did wonder if it was to stop any "panel drumming" on ours it was soaking wet.

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                      • #26
                        Originally posted by S49 View Post
                        I did wonder if it was to stop any "panel drumming" on ours it was soaking wet.
                        I can only imagine, after they spot welded the reinforcement pieces to the inner sill they didn't want to cause any surface defects to the outer sill by any form of welding. Pu sealant widely used on the under body would have been difficult to do due to access. The answer they came up with after numerous high power meetings....lets squirt some expanding foam in there, no one will ever see it until well after the body warranty has expired!

                        Sent from my SM-G930F using Just T4s

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                        • #27
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ID:	266073 Here's ours. You can see the foam in the first photo. We put an inner sill in to. Been in the motor trade for 35 years but the first proper bodywork I've undertaken, chuffed with the results so fair. Yours looks as interesting a project as ours. Loving your thread.

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                          • #28
                            Originally posted by Jonny888 View Post
                            You're right mate, VW etc spend millions on R&D and yet they slip some really stupid ideas into the mix.

                            Sent from my SM-G930F using Just T4s
                            They are not alone, reliant had a brilliant one with their first sports cars, thry had a "flailing arm" front suspension set up which was deemed as unsafe at any speed. However Ray Wiggin (the then md) said we are using them cos we have loads on the shelf.
                            Alfa went into production with nissan. Ok so you think a car that looks great (like an alfa) with build quality (like a nissan)
                            Oh hell no the management panel decided thst nissan would design it and alfa would be responsible for build quality!!
                            Mk5 ford escorts were pushed out on the public nuff said..
                            Austin rover built cars into the late1980s that were not only built of rust but also with tech that was designed in the 1940s (Morris minor front suspension)

                            The first 2 mx5 evolutions were built with intentional rust traps in structural places!

                            Sent from my SM-G960F using Just T4s

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                            • #29
                              Always said that of the BL cars of the 70's and 80's.

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                              • #30
                                Originally posted by S49 View Post
                                Always said that of the BL cars of the 70's and 80's.
                                And they were shocked when the UK car market fell on its arse!

                                Sent from my SM-G960F using Just T4s

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