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post #1 of 8 (permalink) Old 16th September 2013 Thread Starter
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Rust on a Clio Mk1 1.2 '97

Hi - so my offside lower sills are rusted through, one where it meets the wheel arch, the other a little further from the wheel arch.... In fact at both front and rear offside 'jack points'. The thinner steel is completely rusted through where it meets the stronger, thicker 'spine' of metal that runs down the bottom sides - leaving two noticeable holes. And at a couple of points the metal 'spine' is eaten through too. It doesn't help that I dug out the rusty bits, before I realized just how bad the problem was, which led to 'chase the rust'...

As it is I think it's an MOT fail with cost of proper repair outweighing the value of the car.

I would like a second opinion though. Got some photos here to show you. In the photos bear in mind, although pretty ugly, what you see is mostly 'sound' metal.

Perhaps some way I could just rust treat it and cover it up? A sill cover??

Will need a new car soon! But could do with squeezing through another 6 months if possible. And importantly, having had a good old look, I honestly think it'll be 'safe' for another year, if I can treat this rust... and can squeeze it through the MOT lol

Thanks very much in advance.
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post #2 of 8 (permalink) Old 16th September 2013
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Re: Rust on a Clio Mk1 1.2 '97

Hi Tony,

I think that a new section of steel plate needs welding there.

It doesn't have to look pretty, just be safe.

There are plenty of companies advertising mobile welding, so I'd be tempted to get a few quotes before deciding.



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post #3 of 8 (permalink) Old 16th September 2013
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Re: Rust on a Clio Mk1 1.2 '97

That looks a definite MOT fail, but if the main part is sound then plating over may suffice. But do check out the cost of replacing the whole sill compared to having plates welded over the holes, the cost might not be much different and a new sill will make the car look better if you are planning on selling it later.
My Astra failed its MOT as the rear arch had corroded into the sill area (only by 2"). The garage said they would repair it and I was assuming they would fit a part panel. Instead they plated it over with thin gauge plate and I was shocked how much they charged for doing this .. I'm sure I could have had a new sill for a similar price as I had one fitted before on my old Ford Sierra so I had the expected cost in mind.
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post #4 of 8 (permalink) Old 16th September 2013
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Re: Rust on a Clio Mk1 1.2 '97

What can start out as a minor job can turn into a nightmare when you start grinding to find decent metal.
If the drop down flange and floor are rusty it can quickly turn into a major rebuild.

If you can do it yourself, maybe worth it.
Paying someone could get expensive.

Have a read through this thread to see what I mean.

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post #5 of 8 (permalink) Old 18th September 2013 Thread Starter
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Re: Rust on a Clio Mk1 1.2 '97

Thanks for your replies. Short of bodging it though the MOT I think costs will be too much. I know it's still safe for a few months, but with these visible holes it will fail, certainly. It's a case of, in my judgement it's not unsafe as the rust is local and hasn't spread too far, but an MOT inspector will fail it.
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