HOW TO: Replace outer sills
Sills rotten? Here’s your step-by-step guide to replacing them at home.
Are your classic Ford’s sills rotten? Here’s your easy-to-follow guide to replacing the outer ones at home using basic tools.
When rust has claimed a complete outer sill, it’s wise to replace the entire section rather than attempt to fabricate numerous short-term patches. When fitting either a complete New Old Stock panel or a full reproduction part, the remains of the original outer sill must be unpicked from the car’s structure so the new part can be located accurately.
However, because full sill panels are unavailable for many classics, the fitting of a non-original skin sill might be your only option. The MoT test classes these as a large repair piece and therefore they must be welded continuously.
Unfortunately, few outer sill replacements do not involve further work. Depending on how extensive the corrosion is, once the sill’s removed you may have to execute home-made repairs to the A, B or C-posts, floors and the inner sills, all of which must be welded continuously. Be prepared for the additional work.
The rusty outer sill can be cut away with an angle grinder fitted with a metal-cutting disc, but be wary of accidentally damaging the adjacent panels.