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corroded sill pictures

David43

David43

New member
Here are lots of photos of the corrosion on my 944

http://s1245.photobucket.com/albums/gg586/David4343/Porsche%20944/sill%20corrosion/

I hope to fix all this and will post photos of how I get on.

Dave
 
The rust damage is worse than some cars I've looked at on the scrap heap.

Good luck with the repair - fair bit of work there but it is fantastic to hear that you intend to save it.
 
I was going to give up and break the car but I have seen worse examples that have been rescued on some of the internet sites.

I'm not sure my welding is up to it but I am going to find out.

Keep your fingers crossed for me.

Dave
 
Well Dave I wish you luck and admire your tenacity , I myself will tackle most things but this I'm affraid I'd walk away from. Due to what you call the sub frames being so corroded something this big should be done using a jig, not something anyone can do in there garage. If your going to do this be sure to take measurements of all major fixing points before cutting anything, I'd also reccomend that you build your own small jig for the torsion bar and associated mounting points to ensure when you start welding nothing moves out of line. This jig not only needs to ensure that the sub frames remain inline but also they are the correct distance from the front of the car. Therefore the jig needs to be mounted somewhere on the chassis that you know to be true and solid. I'm not trying to put you off Dave just trying to say that jobs this big need to be thought out and planned ahead. Normally for a job this big the bare chassis would be mounted on a four poster with a set of Porsche 944 jig plates attached, thus the chassis is held square at all times so the cutting and welding can proceed.

Good luck

Pete
 
Jeez!, how does a 1988 car get that rusty?, mine is 5 years older but looks like new in comparison, the rotted areas in your photo's look to be in roughly the same condition as a 1959 frogeye sprite that my father restored, the good news being that the frogeye went on to win awards at classic car shows, what you have on your side is free labour of course, good luck with the repairs it will be great to see the finished article, my car needs much less work to re-commission (if I used my head i would just buy another one in A1 condition) but I think you'll agree that much of the reason we have these cars is that we enjoy working on them, keep the photo's coming
 
Yes its much worse than I had expected. The sills were fitted with fiber glass turbo body styling covers.

Maybe they trapped water and made the sills corrode quicker than normal.

Looks like the car has been off the road since 2008 - sitting in a lake I guess.

I wanted a project ......
 
don't worry david it looks alot worse than it is. I've pm ed you my no give me a call and i will talk you through what you need to do.I replaced more metal on mine than you will have to cut away.Loads of people will look at this and crap themself but be brave it can and will be fixed.By the way looks like some monkey made a mess of fixing it before and that has probably made it worse than it would have been.
 

ORIGINAL: POR1983

Jeez!, how does a 1988 car get that rusty?, mine is 5 years older but looks like new in comparison
Click to expand...

Mine is a 1985, the last of the early dash cars and also looks like new inside the sills and suspension points, it was the main reason for buying it. Is it true the early cars had better galvanising?
 
Fair play to you David for having a go. As mentioned, if you take your time and are methodical then there's no reason why it should be too difficult, will just take some time

Looking forward to seeing your progress

Cheers
Andy
 
ed325i how much gas did you use. It looks like the bottle that come with the welder don't last long so I map planning to buy/rent a large bottle.
 
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