The Usual Sills!

[chickenjohn]

Just goes to show that WHAT A TERRIBLE IDEA IT IS TO FILL YOUR SILLS WITH FOAM! Will burn and make welding a nightmare, and traps water against the metal of the car promoting rust.

WHY ON EARTH DO PEOPLE THINK THIS IS A GOOD IDEA??

(sorry for the caps, but I'm annoyed when I hear/ see such bodgery and monumentally stupid things done to classic cars- just use cavity wax to protect your sills! That is what it is designed for! Builders foam is designed for filling gaps/ insulating buildings.)

BTW That rear of sill is from a saloon, the traveller panel in that area is different which was the original question at the start of the thread. And the absence of that panel on a traveller may be the reason why the boxing panel is visible!

[chickenjohn]

Yea - the foam's going to be a right pain. It has been put everywhere there is a cavity.

The rot is bad enough to justify replacing the whole floor to sill section from front to back. So I'll be hacking it all out anyway. So much for it being a quick patch-up job. I'm leaving it on its side for the moment while I get my Pick-up sorted.

Good idea! That is the right way to deal with the rust, cut it all out and weld new panels in!

[xpress]

foam in sills .. words fail me. goes against every bit of common sense.

[JOWETTJAVELIN]

Wind the windows down.

2dr rear windows are recessed enough anyway.

[bmcecosse]

BMC thought foam in sills was a good idea.....the early Minis had foam filled sills. Kept them in great condition!

[MarkyB]

From new, maybe, the only Minis I every saw were rotted out so I have my doubts!

[bmcecosse]

I had a very early shell as my autocross car - got bashed in the sill by another car - when I cut it open the interior was perfect - no rust. But the foam was a bl**dy nuisance - although it pretty much melted away in front of the welding flame !