Mercedes w163 sills

[Joderest]

Hi all
Well after a sold year of sorting out the issues on the ML, that's between work, fishing, other jobs, I have come up against a problem I cannot do myself.
I discovered by accident that at some point in the past a poor body repair has been done, that's not a problem as I can sort out the shoddy workmanship, unfortunately it was hidden behind the plastic sill cover, hence why did not see it before. Removing the cover to sort it out revealed a horror, the drain holes have been blocked, and this has lead to rust. The sill is almost through on the left side, but not quite, so ground it back, treated and painted to give me time to sort out. I then removed the right side to find things worse, sill has corroded through in a couple of places and is very poor right at the back. So again just cleaned up and painted.
I now need to start considering having two sills welded in after the old ones are removed, however there is nothing on line about this on the ML, eBay has only one seller of new sills. Does anyone know how involved this is.
I would be looking for someone to cut out old sills, weld new metal in, I can finish it myself as they are not seen so no need for a body type paint finish.
Does anyone know a decent place to try in the East Sussex area or West Kent.
I dread to think what this is going to cost, hope not too much as would be a shame to stop with the car now as all the rest is good.

 

[Joderest]

ok.
i have been to a local firm where i work who perform reconstruction on Landrovers to more than MOT standard. They have said its not a problem as rust is minimal and replacement sills not required, they have part panels made and will just take out the rusty bit on the bottom and weld new metal back. The inner sill is solid.
Cost, between £100 and £150.
Being done next month.
They did say its not the first ML they have done, and some they have seen are far worse than mine. So check those sills under the plastic covers.

 

[wu56Shoozz]

Can you post Photos please? If you have a hole, buy some Dintrol Cavity wax. It comes with a lance and you just feed it in the cavity, slowly withdrawing it (Oooeerr) and spraying as you go. Kills any chance of rust again...

dinitrol cavity wax | eBay

 

[grober]

Unlike the later models? the W163 has an old fashioned ladder chassis under all that bodywork. This means structural integrity is not threatened like saloons where the sills form an essential part of the bodyshell structure. Early versions of that ladder chassis were known to crack mind in the early days [ maybe from off roading?] altho later versions were re-inforced to counter that. Tell em to check the chassis while they are in there.
Mercedes-Benz Forum - View Single Post - W163 Parts Pictures

 

[Joderest]

Thanks, good picture.
As far as i can see the chassis is sound, at some point in this vehicles past someone has coated it in a wax type substance, which is wearing off in places, but i can only detect surface rust, no corrosion.
The sills have corroded at the bottom where they attach to the inner sill upright, and the rust is almost the whole length. It does not go on to the upright, just the flat bottom. When i got the car the drains either end were blocked solid, and poking them out produced about a litre of water each side, so i suspect its been laying on the bottom of the sills.
I have asked the garage to just weld in flat metal all the way across, and i will drill new holes for the sill covers and use a hole saw to produce the large hole for the drains, then a good coat of Zinc primer and then hammeright on top.
I have also asked them to spray the inside of the sill to help the inner seal stay good.
The old girl is worth doing.
I cannot take any pictures as i have already coated them with paint, just to protect until job is done. But as i said, unless the sill covers are removed, none of this can be seen.

 

[wu56Shoozz]

Do what I did then, using Bilt & Hammer Dynax S50 I lifted the sill cover and sprayed the outer surface of the sill as no one is going to see this, then replace the sill cover. Job Done.. no more rust...

Dynax S50 | High Protection Rust Proofing Cavity Wax - Bilt Hamber