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Boxster With Sill Rust

I have a 2003 Boxster with a patch of rust on the very bottom (horizontal section) of the passenger side sill half way along. It's about 10cm long and in places the metal is pretty thin. Having scraped to the edge of the rust the sill, paint and stone chip look original. There is no obvious evidence of previous repair.

I thought that with the shell being galvanised this sort of thing should not happen although the car is eighteen years old.

Anyone else had this experience and performed repairs?

 
Galvanizing is usually pretty good but, in all fairness, it just hold off corrosion. You only need one or to 'nicks' in the galvanizing to expose the bare metal underneath and then the rust starts.

I had a 3,2 Carrera that was fully galvanized but at 16 years old it needed 4 new wings, inner and outer sills and repairs to the inner wings. Whoever had it prior to my ownership must have washed it with salt water!

I hope you manage to get this sorted and stop any further rust, but keep an eye on it.
 
As Peter has said usually stone chips in this area exposes bare metal the rot sets in if stone chips are not repaired as they occur.
All the best getting it sorted.
 
A few months back I found a very local rust spot right where the OSR wheel arch spat comes to the sill.
Not perforated, but rusty.
So, a stone went through everything to expose the pin spot and nature took it from there. I would not rule out Porsche manufacturing quality...

All diy fixed but these cars are getting on now. Mine is a 2009 987.2
Galvanised coating is not like the galv on a farm gate, it is very thin.
Galv works by gradual sacrificing to the elements before the elements at through to the steel, it will not last forever and is itself very soft and prone to mechanical (ie stone) damage, hence the 3.2 911 rotting over time above!
 

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