One of our current ongoing jobs in our forever busy workshop is on a 3.0 LTR 1989 Porsche 944 Cabriolet whose sill’s have become extremely rusty through to the inner sills, wings, wing bottoms and more…
The first task, because it is a cab and doesn’t have the hard top roof to support the structure of the car, is to reinforce the doorways to prevent the car warping.
As always the next part is to remove the outer sills and establish the extent of the rust and the damage. Sometimes this is easier said than done due to many different reasons. In this particular case, as well as some reasonably large rust holes a lot of the sill had been previously repaired and the large sections in the picture below are actually all filler which is never a good sign.
We carefully cut and remove the outer sill ( or at least what’s left of it ) ensuring not to damage any of the surrounding panels that aren’t rusted while trying to never remove more of the vehicle than necessary.
More to come from this project as we progress through it so if you have a similar vehicle why not follow our progress !!