Sill (Rocker Panel) Corrosion
Symptoms
Paint bubbling along the sills below the doors. Soft metal when tapped. In severe cases, the sill collapses when jacked, and the door gaps change as the body flexes.
Cause
Sills are enclosed box sections that trap moisture. Water enters through blocked drain holes at the bottom of the sills and through the door shuts. Once rust starts inside the box section, it's invisible until it eats through the outer skin.
Fix
Minor: cut out the rusted outer skin, treat the inner structure, and weld in a repair panel.
Major: full sill replacement, requiring removal of the outer skin, repair or replacement of the inner sill, and refitting the outer panel.
Cost: $1,500-2,500 per side.
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