Removing outer sills

[Dado]

Hi guys
Despite spending a hefty wedge of pension on a Bentley workshop manual, I seem to struggle with every job I do not really being covered in it.
The drivers side sill is looking a little worse for wear at the rear with a little frayed and rusty spot underneath.
Now I know lots of you have removed the sills and done lots of work to the inner sills and replaced the outer sills, but what is missing from the manual I have is exactly how to remove the b!**dy things, I can see all the screws underneath but cant see any upper fixings.
Looking at the pictures of new sills and some of the threads on here it would appear the lower part of the front wing has to come off but what about the rear and the door area?
I asked at my local body shop and they quoted me just shy of £700 per side to supply and fit new outers, but there is no margin for any work to the inner sills if required.
Have decided to do what I can myself but just don't know how to remove them, can anyone help point me in the right direction please.
Cheers DD

 

[Kenhayes247]

HI - Google classiccoach works or use this link, https://www.classiccoachworks.org/z-stripdown-guide
they have quite good explanations etc of how to strip a Z3

 

[andyglym]

Hi mate, this may help.

BMW Z3 Sill Removal and Protection

BMW Z3 Sill removal and protection Article supplied by z3cade (Liam) Jack up the car and place on axle stands Remove wheels Remove rear arch liner Remove kick pannel trim and door rubber Remove kick panel plastic plug Remove kick panel...

zroadster.org

 

[Peter1450]

Got to love that quote……£700 per side

 

[Dado]

Thanks guys very helpful, especially with the pictures for clarity, will get on with it when weather is a bit warmer, have a few weeks to source some new sills too.
Just to be fair to the body shop, they are mega busy, short staffed and probably priced to put me off getting it done, and it was for genuine BMW parts and probably at the full RRP plus mark up.

 

[Peter1450]

Probably more expensive now than last year but I bought a genuine pair for approximately £300 from Cotswold in Cheltenham.

 

[Lee]

There's a brand new pair for sale on here at the moment for £350. @Mazza

 

[Dado]

Thank you for the info, I know some people will turn their nose up but was looking at the grp ones from the Z3 kit car site mentioned in an earlier post, at least they wont rust again....
I know someone on here said about sloppy tyre man jacking up wrongly but the 1mm thick OEMs wont take much abuse either so will think on it for now.
Thanks again DD

 

[Andyboy]

I wouldn't. Steel sills if painted off the car and Waxoyled before fitting will last another 20-30 years or more.

They are a piece of cake to fit. Your inner sill will be fine, just needing a good clean and possibly a tickle with a wire cup brush in a grinder followed by some Kurust or similar.

 

[colb]

You will need some replacement trim clips for the door threshold covers, they tend to snap when you dismantle the trim, you can find them on ebay for resonable money, they sell them in packs of 10 so buy 2 packs

Pardon our interruption...

Worth considering sourcing stainless self tapping screws with hex heads to replace the steel ones along the underside of the sills 4.8 x 16 mm size available on ebay but you will need stainless washers to increase the head size so they clamp up well. Suitable washers also on ebay.

https://www.ebay.co.uk/itm/181786652459?var=480728974706

https://www.ebay.co.uk/itm/163939882420?var=463555230533

 

[Dado]

Thanks again for all the info guys, okay maybe will go for the metal sills, will start hunting for the best price.
I do have a big trade box of all types of plastic fastners so will check that first, the stainless screws are a good idea and I do have a big box of those left over from a Lambretta rebuild so will check those too.
Very helpful information, thank you again
DD

 

[notsoeasyaspie]

Probably more expensive now than last year but I bought a genuine pair for approximately £300 from Cotswold in Cheltenham.

I'm also looking for sills and I've been in touch with classic coachworks as well as quite a few dealerships. The GRP sills (according to the sellers) seem to be selling quite well but very few people are sharing their experience with them. Peter is right though the prices have gone up, I'm not sure if the price below includes VAT too. The state my sills are in at the minute they're more rust than metal and not really worth repairing. Good luck, they're pricey wherever you go it seems

 

[Dado]

Hi, Yes the shop quoted £172.48 + VAT = £206.98 per side and I'm in Milton Keynes so would expect that is the local BMW dealer.
As you say not a cheap exercise, but due to having to do this outside will wait for the weather to improve before starting, have compressor and spray gun, so will save the cost of labour, still going to be getting on for £500 with paint, underbody stuff (inner sills) and new fixings.
Don't know the real state of the sills till removed but the right side has definitely got some missing underneath, maybe get away with rub down and paint on the other but will find out.
Andyboy says the metal ones will last another 20 - 30 years but I won't, and the existing ones haven't lasted 20 years either.
Cheers DD

 

[t-tony]

I'm guessing Andy boy was quoting "20 years" as a round figure and unless your car was built after 2002 its taken 21 years to need to replace them so really that's nit picking isn't it?

Tony.

 

[Jack Ratt]

I bought a set of GRP sills last year for my silver zed but haven't fitted them yet. My original sills are well past it and can't be saved. The GRP sills need a bit of fettling and a skim of filler in places but they'll be fine I'm sure. I'm waiting for some good weather before I start work. I'm going to fit new front wings too. Both my Zeds are SORN at the moment. I haven't driven the black one since 2020 and the silver one hasn't moved since it failed MOT last Feb.

 

[Andyboy]

Andyboy says the metal ones will last another 20 - 30 years but I won't, and the existing ones haven't lasted 20 years either.

Did you remove and Waxoyl the sills when you bought the car new?

 

[Ianmc]

My April 1997 build Z3 (almost 26 years old now) has original outer sills with no significant corrosion; perhaps the early cars were better built!!!!!!!

 

[PCD]

I agree. I have removed both sills on my 1998 year recently and they were in excellent condition, as were the inner chassis members. Only slight surface rust at the ends which which were cleaned up, wax oiled etc.

 

[Dado]

I didn't buy the car new, it was a replacement for my work supplied car when I retired 8 years ago, not even sure why I picked a Z3, purely on the look of the car I think and it was the first one I looked at too.
I admit that the first look at it then was not an AA type inspection but there was nothing wrong with it of note, and my knowledge of Z3's was limited.
It's a shame but it has to live outside all the time so I guess the weather has taken it's toll In the 8 years I have owned it.
I also did not know about this site either, maybe if I had, the sills might have been taken off and waxoyled then, but hey not everyone is that aware eh.
With all the cars I have owned over the 56 years I have been driving I have been lucky enough to be able to say body work issues have been no more than stonechips or very minor scratches, apart from outright crash repair stuff done by bodyshops.
Biggest issue with this is doing it on a sloping drive one side at a time, and maybe the cost.....
Thank you for all the responses, I do find it a bit reassuring that like minded people are 2 clicks away.
DD

 

[Andyboy]

I agree. I have removed both sills on my 1998 year recently and they were in excellent condition, as were the inner chassis members. Only slight surface rust at the ends which which were cleaned up, wax oiled etc.

Both sills on the 1998 car I restored last year were knackered - a garaged car with very good wings and inner sills and 80k from new.

A lady came to see me a year or so ago with a Fiji green 1998 1.9 with various issues including seat runners, window regulators, cam cover gasket (stripped threads) and worst off all, MOT work. The thing was as rotten as a pear so by refusing to quote for repairs (it costs what it costs) I managed to extricate myself from it.