Sill Corrosion (Inner and Outer)
Symptoms
The outer sill skin bubbles, softens, and eventually perforates. In advanced cases, the outer sill crumbles when prodded. The inner sill -- the structural member -- rots from inside the box section and loses its load-bearing capacity.
Cause
The sills are box-section steel with drain holes at the bottom. These holes block with dirt and underseal, trapping water inside the cavity. Corrosion works from inside out, so by the time you see exterior rust, the inner sill may be compromised. The sills are structural -- they carry bending loads and support the door hinges.
Fix
Replace both inner and outer sill sections.
This requires stripping the car to bare metal in the sill area, cutting out the corroded metal, and welding new panels.
Quality repair panels are readily available from Moss Motors, British Motor Heritage, and others.
Cost: $1,500--3,000 per side for professional work.
DIY is possible but requires competent welding skills.
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