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  1. #21
    Jonny888's Avatar Now you're learning (Copper)
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    Quote 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

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  2. #22
    Jonny888's Avatar Now you're learning (Copper)
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    Quote Originally Posted by Hans View Post
    U don't fuck about. Good job mate

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    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!

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  4. #23
    Greeny gtc's Avatar Unemployed (Platinum)
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    Quote 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

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    I have heard vw doing things like this before, b5.5 passat arches rotted out within 3 years b3couse of a similar design floor.

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  5. #24
    Jonny888's Avatar Now you're learning (Copper)
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    Quote 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.

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    You're right mate, VW etc spend millions on R&D and yet they slip some really stupid ideas into the mix.

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  6. #25
    S49's Avatar Privileged
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    I did wonder if it was to stop any "panel drumming" on ours it was soaking wet.

  7. #26
    Jonny888's Avatar Now you're learning (Copper)
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    Quote 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!

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  9. #27
    S49's Avatar Privileged
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    Click image for larger version. 

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ID:	10922 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.

  10. #28
    Greeny gtc's Avatar Unemployed (Platinum)
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    Quote 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.

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    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!

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  12. #29
    S49's Avatar Privileged
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    Always said that of the BL cars of the 70's and 80's.

  13. #30
    Greeny gtc's Avatar Unemployed (Platinum)
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    Quote 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!

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