Critical Body
Structural Rust, Sills and Rockers
Symptoms
Bubbling paint along the sill line, visible rust perforations underneath, soft metal when prodded.
Cause
Water and road spray enter the sill cavity through drain holes, stone chips, and deteriorated seam sealer. The enclosed box section traps moisture. Once rust starts inside the sill, it spreads quickly.
Fix
Minor surface rust: treat with rust converter, seal, and paint.
Perforated sills: cut out the rust and weld in new metal (repair panels are available for some models) or replace the full sill section.
A proper sill repair costs $2,000-5,000 per side.
Bog over rust is not a repair, it's hiding the problem.
Cost mentioned in fix
$2,000-5,000 per side
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