So, like all old car owners, I dread the badly done bog job. It seems the guy before me liked doing it himself, and loved using bog (badly). There's a huge lot coming through in my sill at them moment ....and in the passenger door.... and in the passenger front guard.... I'm not too worried about the doors and guards because I'll be able to get them new from somewhere, but I'm not too sure about the sill. I've heard these are very expensive jobs to do if you were to go to a panel beater, so I wanted to know whether anyone had done their own sill repairs before. Anyone in SA ever bought new sills for their 1200? And has anyone ever put them on themselves? We'll hopefully be getting a Mig welder or something like it soon, so is it possible to do it at home, and save some $$$$$??? Cheers guys!!!

My wagon has good sills but before I got this one I had a Valiant Charger I replaced sills in. Rather than buying thin overpriced reproduction parts, I suggest you do what I did and cut a cross-section out of the sill panel and take it to your local sheetmetal/engineering company, they can roll your sills from the sample, and even use thicker material if you so wish.To remove the old sills you'll have to bare metal along the bottom seam so that you can see the spot welds and drill them out one at a time. As for the top you'll most likely have to clean cut them from front to rear along the top edge.

no worries. Cheers mate. We'll see what me and my dad can do.

hey i just brought 2 new sills for me ute left and right hand side and they were piss easy to put on and if done righ dont need any bog
i accidently hit one of mine now needs little bog GRRRRRRRRRRRRR anyways it cost me bout 100 bucks for the sills and bout a day to fit them

My first 1200 coupe had plastic side sills (Bog & newspaper). The panel beater who replaced them got some galvanised steel bent to the same profile & replaced them.A sheet metal supplier might have the name of a supplier. When you've got the side sills off, plate the inside of the inner rail with the same steel. This will make the car nice & stiff, which always makes the car feel better to me.

A long time ago, in a suburb far, far away, there lived a yellow LC Torana. Sills rusted to an inch of their lives. With no welder or money on hand except a 4kg tin of bog and a slab of VB the problem solved itself. Drink the slab, slide the cans inside the rotten sill like loading a shotgun and trowell the bog over the cans into the sill... Looked the stuff but I would hate to think of the cars fate now.

P.S. Not my dodgey job by the way. Any repair better than that one is worth being proud of!

I assume bog = Bondo (filler) - Yes, I've replaced the sill's, matter of fact I'm in the middle of doing them both, got the right side done, you'll see in the pic's - time consuming but not too difficult to do right. If you want a f***ed up sill then shove beer cans in there, smear mud on it & think nothing of it, on the other hand if you want to actually replace the panel then heres one method...







sorry, cant seem to get the orientation right on the above pic - thats the rocker cut out w/22 Ga. steel strips welded behind the cut portion of the rocker/sill. the replacement metal I pounded into the proper curve & then spot welded it all in.

theres a little piece that went under the bottom of door that needed replacing too.









heres another of the sill patch & quarter panel patch welded in - thats coated w/POR-15 paint BTW...





theres a down & dirty way (beer cans & mud, gotta give em credit for creativity though) or an actual long term repair, certainly your choice. It's not that hard to do right, just takes some work & obviously more time.

Good luck!

Evan,
Is that a rotisserie your ride is being held up by? If so I am very jealous.

Kelly

Kelly, Not quite a rotisserie, two individual 4 caster stands I made out of 1.5" square stock steel which came from a back down loading dock railing that I removed from commercial remodel. The railing were 25" each, 6 rung high, too much good steel to recycle so I cut it into 8' lengths. Made those two stands & still have lots left over.

One stand bolts thru the front frame channel behind the valence & the rear has saddles facing upward that catch the rearmost piece of the frame behind the spring shackles. they work amazingly well, I'm quite happy with them. It was a good welding project to sharpen my skills on!

Kelly,
E-mail me your phone # so I can call you & pester you at work for parts BS! I've got a request for you please!

evanp123@comcast.net

Thanks, Evan