Hi guys I recently bought a VRS 05 120,000 as a project car and the front sills are pretty knackered From what I believe to be due to incorrect placement of the jack stands, as the sill lip was quite bent and crooked. The rear sills seem okay.

 

There are some holes in the floor near the sill as shown, and I particularly have a problem where the floor meets the inner sill to create the sill lip. The inner sill has rusted away in one section along with the floor (first picture) and it’s come away completely from the lip. 

 

The next sill layer underneath this is fine, and the outer sill is fine from the point of which it meets the door to the inner door frame (it’s the undercarriage outer sill that needs cutting away.)

 

I’m wondering if anyone here has done any sort of repair for this and what would be the best way to fix this issue. I’m a novice welder and was hoping for there to be a little bit of patch work but it seems like a new floor section would need to be fabricated along with a section of inner sill and welded together in place so I may have to find a welder. 

 

Cheers guys. 

 

 

 

 

 

So 

 

I used a drill with wire brushes all the way down to the metal. Then painted with red oxide paint. Then painted over with waxoyl. I then painted same colour as the car above towards the doors.

 

I was lucky no holes but yours might need bits cutting out as the rust will be on the inside high chance. So you could weld and patch but you be doing it again soon. It's better to try cut around the hole areas to make sure the rust has gone both sides.

Edited 20 August, 20214 yr by Kelly_Heroes

Just wondering where to cut really. I was surprised to find that the Fabia has essentially a double sill (shows how well made these cars are!) so I’m thinking of cutting more away from the floor in order to get access to the inner sill and weld a plate in