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Sill removal and rust prevention

Discussion in 'Z3 Roadster & Coupé' started by z3cade, Dec 31, 2011.

  1. z3cade

    z3cade Zorg Guru (III)
    East Anglian Crew

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    Sill removal and rust prevention


    Jack up the car and place on axle stands
    Remove wheels
    remove rear arch liner

    ai866.photobucket.com_albums_ab225_cade37_sill_20fix_DSC03118.jpg

    Remove kick pannel trim and door rubber

    ai866.photobucket.com_albums_ab225_cade37_sill_20fix_DSC03119.jpg

    remove kick pannel plastic plug

    ai866.photobucket.com_albums_ab225_cade37_sill_20fix_DSC03120.jpg

    Remove kick pannel by lifting up

    ai866.photobucket.com_albums_ab225_cade37_sill_20fix_DSC03121.jpg

    You may brake some plastic clips so remove broken clips from holes

    ai866.photobucket.com_albums_ab225_cade37_sill_20fix_DSC03123.jpg

    Remove front arch liner

    ai866.photobucket.com_albums_ab225_cade37_sill_20fix_DSC03124.jpg

    Remove screw from front arch, top front of sill (use 10mm ratchet)

    ai866.photobucket.com_albums_ab225_cade37_sill_20fix_DSC03125.jpg

    Remove three screws for the small side pannel, detatch side repeater and remove

    ai866.photobucket.com_albums_ab225_cade37_sill_20fix_DSC03127.jpg

    Get a friend to help, but a good friend not a nutter... s:rolleyes

    ai866.photobucket.com_albums_ab225_cade37_sill_20fix_DSC03128.jpg

    Remove screws from under the sill

    ai866.photobucket.com_albums_ab225_cade37_sill_20fix_DSC03130.jpg

    Remove screw from rear arch

    ai866.photobucket.com_albums_ab225_cade37_sill_20fix_DSC03131.jpg

    Remove small plastic trim from inside door and remove bolts that hold rear arch to allow better access for the screw behind it

    ai866.photobucket.com_albums_ab225_cade37_sill_20fix_DSC03132.jpg

    Remove finnal bolts from top of the sill that were under the kick pannel and remove sill

    ai866.photobucket.com_albums_ab225_cade37_sill_20fix_DSC03133.jpg

    Clean up box section and check for rust

    ai866.photobucket.com_albums_ab225_cade37_sill_20fix_DSC03137.jpg

    Treat areas with rust with your prefered products

    ai866.photobucket.com_albums_ab225_cade37_sill_20fix_DSC03138.jpg

    I used zinc 182 primer, clear waxoyl spray for inside box sections and original waxoyl underseal

    ai866.photobucket.com_albums_ab225_cade37_sill_20fix_DSC03139.jpg

    Treated rear box section

    ai866.photobucket.com_albums_ab225_cade37_sill_20fix_DSC03140.jpg

    Treated front box section

    ai866.photobucket.com_albums_ab225_cade37_sill_20fix_DSC03141.jpg

    Sand down any rust found on the sill and treat with your desired products

    ai866.photobucket.com_albums_ab225_cade37_sill_20fix_DSC03143.jpg
    ai866.photobucket.com_albums_ab225_cade37_sill_20fix_DSC03144.jpg

    Now just reverse the removal process and replace the sill, Job done :-bd
     
  2. MAURICE THE MARTIAN

    MAURICE THE MARTIAN Zorg Guru (V)
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    Wll done Liam,glad mine are plastic ;)
    :ymalien:
     
  3. pete59

    pete59 Zorg Addict
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    brill!!! :D great and very clear pics,do fancy doing mine,great hourly rate.lol
     
  4. Garythefish

    Garythefish Dedicated Member

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    Great post Liam s:D
     
  5. swamper

    swamper Zorg Guru (V)
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    great wright up s;)
     
  6. Aceman

    Aceman Moderator
    British Zeds 3rd Party Trader

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    Great tutorial Liam, want to do this myself sometime so many thanks. :-bd
     
  7. Looks like he sat down on a spanner or something...... :ymapplause:
     
  8. GazHyde

    GazHyde The Gaz Monkey
    Staff Member Administrator Global Moderator British Zeds

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    Great work Liam,

    I think anyone could follow that! I have put a copy in the Z3 knowledge section, and will add it to the wiki next year ;)

    Gary
     
  9. z3cade

    z3cade Zorg Guru (III)
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    Thanks guys yes feel free to use it. Hope it helps out anyone wishing to do it.
    I'd recomed doing it to help prevent rust forming in the future as these areas seem prone to muck collecting and staying damp..
     
  10. HornelZ3M

    HornelZ3M Zorg Addict
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    Damp, what does that mean.. Happy new Year mate, great write up. :ymparty: :ymparty:
     
  11. r37

    r37 Dedicated Member

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    might also be worth putting some waxoyl inside the door aswell. Had my door card off to grease the runners and the bottom was filled with a horrible smelling brown mixture, other than that great write up.
     
  12. badman gee

    badman gee Guest

    enjoyed the day mate, mine next.

    :D
     
  13. badman gee

    badman gee Guest

    oooh it felt good s:mrgreen
     
  14. jonco

    jonco Zorg Guru (III)
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    Excellent guide - I have so far only removed one side of my 98 1.9 Zed. I was quite pleased/relieved that the actual sill was in good condition except for expected moderate surface corrosion in the wheel arch lower voids. These are easily repairable but of more concern was corrosion in the lower front corner of the wing panel which was only removed for access. Refer to pics -there was a `sealant' run along the length of the bottom edge and it lost some contact in the front corner creating the obvious mosture trap. The contour line of the rust is where the sealant was. The `sealant' resembled rock hard putty and was very difficult to dig out without damaging the metal and therefore I have only cut it back to clean metal. Don't know if this is original or a previous owner's diy attempt. Has anybody else got experience of this or a suggested repair/ replacement sealant. I am considering installing an additional plug in arch liner at this point to make Waxoyl injection easier in the future.
     

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