6.9 sill replacement project

[OzBenzHead]

Ryan:  Your sills replacement project has me riveted, as I might soon be embarking on the same project with my latest 116 (another 280SE).

I have been quoted prices for the outer sills and the front end-pieces, and am not too put off by that.  So far.

What I'd like to know is how is the back end of a sill closed off?  Is another part required, or is it already part of the sill moulding - or perhaps part of the back mudguard panel?

And ... what if, when I get the old outers off, I find that the inner sills are cactus?  Can they still be purchased?  And the jacking-tube sections?

[s class]

You can buy inner sills, I didn't get a price.  I would be very reluctant to replace inner sills because of the risk of distorting the chassis alignment this would entail.  In my case (which I believe is typical), the outer sill is really rotten, but the inner sill is generally sound, barring some small places.  You can patch these areas of the inner sill.  In my case, the rot in the one part of the inner sill extends into the adjacent floor, and that is why I elected to buy part of a car.  I will 'cut and paste' the relvant bit of inner sill and floor as one item. 

You can buy the rear jacking point separately, but its VERY expensive.  The front jacking point is not available separately.  It comes pre-attached to the inner sill.  In my case it will come with as part of the 'cut and paste', but from investigating the area, I see no reason why a front jacking point could not be transplanted by itself, if your inner sill is good in that area. 

The rear end of the sill does not have a separate closure piece.  It is closed off by an extension of the rear wheel arch.  Mine has some rot there too, but I will patch it with ordinary new steel. 

Let me get som pics up.....

[s class]

OK here's the 'section' I purchased.  Guess you could say I now own 2.1 W116's 




I took a number of photos of the cross-sections, because its actually very interesting to see how everything is put together :

Below is a top view of the A-pillar area.  You can see where the A-pillar is spot welded onto the outer sill.  These areas will need to be drilled apart on the 6.9.  there are similar spot welds onto the inner sill, which I will not be interfering with on the 6.9. 




ANother view of the A-pillar.  Man these cars are built solid :




NOw here is a section through the inner and outer sill.  We are looking from the rear towards the front - the cut is just behind the B-pillar.  You can see how the inner sill, outer sill and floor all lap together.




OK then this is impressive : a horizontal section through the bottom area of the transmission tunnel.  Just look at that steel!

[OzBenzHead]

Ryan: Many thanks for those instructive pics.

From comparing the profile of your new sill with the cut-up, have I correctly interpreted inner and outer as per my mark-up of your photo - outer being red outlined and inner being green?

[s class]

Yes, close OBH.  Only you have lincluded part of the floor sheet in the green area.  Check this version - I have identified the floor sheet in blue :

[116Benz]

I'm going to be watching this with interest, I suspect the SEL is going to have that same problem. The passenger side sill has some flaky paint, about the size of a 50 cent piece (an inch-ish) about where the A pillar is welded.

[s class]

116benz, If the rust is restricted to one or two small places, I'd be inclined to just cut out those areas and repair with new steel.

I've elected to replace the whole sill because its extensively rusted and has various dents too.

Ryan

[116Benz]

That sounds like a much better plan...

[koan]

The way a 116 is assembled is a bit of a mystery to me, I've have the pictures of body panels in the picture parts book but they don't help much.

Your pictures are most informative, thanks and keep them coming.

koan

[CraigS]

I'm surprised they didn't put hinges on it and turn it into an additional luggage space - You'd almost fit a set of golf clubs in there !

[CraigS]

Are you planning on using some form of preventative rust treatment on the interior of the sills ? If so, do you have anything in mind - Tectyl, POR15, etc ?

[s class]

Hi Craig,

Once its assembled I will paint the inside via the orofices.  I will probably consider tectyl, though I doubt this car will get driven much, so future decay is unlikely. 

[OzBenzHead]

For continuation of OzBenzHead's rusty sills story, see new thread http://forum.w116.org/interiors-and-exteriors/rusty-and-crusty/new/#new.

[OzBenzHead]

For continuation of OzBenzHead's rusty sills story, see new thread http://forum.w116.org/interiors-and-exteriors/rusty-and-crusty/new/#new.

[OzBenzHead]

Apologies, folks, for the duplicate posting: I kept getting "server error" messages.