How I repaired my sill damage (GQ)

[brw1994]

On a camping trip over the weekend I dented my sill real bad and while in the process of building rock sliders this was a kick in the teeth. I decided to get on it right away and fix the problem. I bought some multi-purpose heavy duty bog (Selley's Plasti-Bond) from work some sanding gear and I was ready to go. This was the first time I have taken hammer to car panel let alone bogging painting etc..

http://img716.imageshack.us/img716/2012/img1040li.jpg (http://imageshack.us/photo/my-images/716/img1040li.jpg/)

http://img339.imageshack.us/img339/6241/img1041yc.jpg (http://imageshack.us/photo/my-images/339/img1041yc.jpg/)

I started out with a big job ahead of me and first asked questions about bogging the whole way or fiberglassing then bogging but ol' mate ThreeDogs suggested a brilliant little idea, Rivet into the sill and pull the dent out to minimise bogging. This was step 1.

http://img826.imageshack.us/img826/6127/img1043k.jpg (http://imageshack.us/photo/my-images/826/img1043k.jpg/)

After this I had to carefully straighten (belt) the step part of the sill and flatten it out. I then used a few more rivets to finish up pulling out the panel as much as I could. This worked an absolute treat and I can't thank TD enough!

http://img405.imageshack.us/img405/4835/img1045rb.jpg (http://imageshack.us/photo/my-images/405/img1045rb.jpg/)

After finishing pulling the sills out as much as I could I finished off the rivets then drilled them out leaving me with a whole heap of holes giving more strength to the bog from the extra adhesion.

http://img402.imageshack.us/img402/7480/img1046f.jpg (http://imageshack.us/photo/my-images/402/img1046f.jpg/)

I mixed up my first batch of bog and went for it. The first coat was a starting point but I had a long way to go to bring it to my standard. So it was just bog sand bog sand etc until it started to take true shape and I was getting pretty impressed with it.

http://img502.imageshack.us/img502/2830/img1047qp.jpg (http://imageshack.us/photo/my-images/502/img1047qp.jpg/)

http://img194.imageshack.us/img194/6967/img1048yu.jpg (http://imageshack.us/photo/my-images/194/img1048yu.jpg/)

http://img171.imageshack.us/img171/162/img1049ze.jpg (http://imageshack.us/photo/my-images/171/img1049ze.jpg/)

I realised I had also bent the bottom of the door too so I grabbed a bit of timber and carefully brought it back to a nice straight line and this worked amazingly!

http://img515.imageshack.us/img515/9819/img1057d.jpg (http://imageshack.us/photo/my-images/515/img1057d.jpg/)

So tonight being the 2nd night after denting the sill I'd say I have a few more to go but this is the detail I like to go to. This is as she sits now, it's almost done and ready to get the lines right and a final sand.

http://img43.imageshack.us/img43/6740/img1055us.jpg (http://imageshack.us/photo/my-images/43/img1055us.jpg/)

http://img855.imageshack.us/img855/8946/img1054cf.jpg (http://imageshack.us/photo/my-images/855/img1054cf.jpg/)

http://img803.imageshack.us/img803/7247/img1053pl.jpg (http://imageshack.us/photo/my-images/803/img1053pl.jpg/)

http://img850.imageshack.us/img850/5516/img1051e.jpg (http://imageshack.us/photo/my-images/850/img1051e.jpg/)

I plan on sanding back both sills once finished, 2x undercoat with Killrust Heavy Duty Primer then 3x Coats or black gloss Killrust and top it off with hopefully an automotive clear coat 2 or 3 coats. I will then checkerplate both sills and all 4 doors under the creased line in the panel on them to cover and proctect them, along with the dent in the passenger door. Don't think I won't keep you all updated! I hope this inspires others to fix their misshaps ;)

[MudRunnerTD]

A belt sander is the best way to get them nice and straight mate. ;)

[brw1994]

Yeh I had a belt sander that I've owned since I was about 9 years old but my uncle blew it up, I bought a random orbital sander today though to try get it right :) Ill finish off by hand with a block though.

[Dales300exc]

I have one a lot worse than that. Wanna fix it for me? Haha

[MudRunnerTD]

Just be a little. Are up with the random orbital. It will be inclined to feather the edges and hump it rather than a solid flat sill. It might look a little lumpy when you lay the paint on it.

Borrow or hire a belt sander if you can mate.

[brw1994]

Sure lol if you really want to make the trip!

[brw1994]

Just be a little. Are up with the random orbital. It will be inclined to feather the edges and hump it rather than a solid flat sill. It might look a little lumpy when you lay the paint on it.

Borrow or hire a belt sander if you can mate.

Yeh thinking about it thats really a much better idea, thanks mud I'll just use my old ryobi with care..

[Dales300exc]

I think its more of a cut out and replace job. Ill take a photo haha

[MudRunnerTD]

can you describe the Rivet technique for us mate? Looks like it worked a treat but not sure how you did that? I get that the rivet hold teh panel but did you just use vice grips or something on the rivet and pull like hell of somehow use a slide hammer on them? Any pics?

[brw1994]

I drilled the holes for the rivets in the lowest points of the dint and using my river gun it takes 2 pumps of the handle to finish the river off so I did 1 pump which left the tail on the rivet and just used pliers to DIRECTLY against the rivet, not on an angle or lever because it stretches the holes. I just keep moving along and it worked perfectly, but I didn't do as much as I probably could looking back on it. I then just finish the rivet off and drill it out

[brw1994]

I think its more of a cut out and replace job. Ill take a photo haha

I would have if I ha the access to a mig but I didn't, I also wanted to test myself out as I hadn't done this before

[MudRunnerTD]

So you had a half done rivet in ever one of those holes at the same time and just worked them all giving little tugs to each to work the steel out? The benefit is that the holes will be an etch for the bog to hold too. Nice one. I will give that a go on my rear quarter i reckon.

Cheers MR

[MudRunnerTD]

i have been told to tac weld to the panel and pull but i dont have a welder ;) the rivets will work well i think.

[brw1994]

Yeh mud that's how they do it in the states, there's a specific tool I saw on YouTube but this is the same principal, all credits too three dogs for this too

[brw1994]

And yeh just worked along and went back over, I probably should have done more though, the more you can do with the rivets heaps less work later on

[brw1994]

Well after almost a week of lunch breaks and after work hours it's almost finished and I am quite excited about the results!

The last run of bog before a sand and paint.
http://imageshack.us/a/img138/396/img1069j.jpg

This is the multipurpose heavy duty bog I used, quite impressive.
http://imageshack.us/a/img841/5446/img1064gd.jpg

Neat little orbital that helped more than I could ever thank it for, for $109 who can complain?
http://imageshack.us/a/img832/8128/img1063db.jpg

After 2x Undercoats and 3x Black Gloss coats before I put some clear coat on tomorrow and the day after
http://imageshack.us/a/img850/545/img1085u.jpg

My checkerplate doors, only finished 1 as I was curious whether NP.com reckons I should use silicone behind it or not.. If I don't get some feedback I'll have to post elsewhere :\
http://img600.imageshack.us/img600/8301/img1089sy.jpg (http://imageshack.us/photo/my-images/600/img1089sy.jpg/)

[MudRunnerTD]

Bump to add some pics to this.

[MudRunnerTD]

So after seeing this thread I used this technique to sort out rear quarter panel damage. Saw this thread linked today and bumped so I could add some pics. I might do a separate thread too.

So here is the dent

433334335043351

Here is the tools I gathered

43334

Here is the system

43335433364333743338

Out with the vice grips and slide hammer

4333943340

Patience, reset, red rill,

43341433424334343344433454334643346433474334843347 43349

Worked a treat. I laid fiberglass over the panel then bogged and sanded then painted. Came up a treat. Thanks for the idea.

On a side note! Next trip out I smashed this panel again, it's ok though! I also smashed the other rear quarter and both front quarter panels!!! Happy dayz


Sent from my iPhone using Motorculture mobile app

[Alitis007]

Instead of making swiss cheese out your quarters you could get a straight tip for the sliding hammer and tack weld it onto the panel and pop it out. If you tact the sliding hammer to the lowest part of the dint you would only need to pull it out a couple of times!

[MudRunnerTD]

Instead of making swiss cheese out your quarters you could get a straight tip for the sliding hammer and tack weld it onto the panel and pop it out. If you tact the sliding hammer to the lowest part of the dint you would only need to pull it out a couple of times!

Yes I agree a spot weld would be a winner. This worked very well though for anyone without a welder. A cheap ass pop river kit from Super Cheap is $12 in the bargain bin.

[pickers]

Well there goes the No Drill Policy :1087::1087:

[mudski]

So after seeing this thread I used this technique to sort out rear quarter panel damage. Saw this thread linked today and bumped so I could add some pics. I might do a separate thread too.

So here is the dent

433334335043351

Here is the tools I gathered

43334

Here is the system

43335433364333743338

Out with the vice grips and slide hammer

4333943340

Patience, reset, red rill,

43341433424334343344433454334643346433474334843347 43349

Worked a treat. I laid fiberglass over the panel then bogged and sanded then painted. Came up a treat. Thanks for the idea.

On a side note! Next trip out I smashed this panel again, it's ok though! I also smashed the other rear quarter and both front quarter panels!!! Happy dayz


Sent from my iPhone using Motorculture mobile app
Lol. Daz didn't show what he did to his face though. Luckily I got a pic. I must say it looks good.

43456

[Irish]

Instead of making swiss cheese out your quarters you could get a straight tip for the sliding hammer and tack weld it onto the panel and pop it out. If you tact the sliding hammer to the lowest part of the dint you would only need to pull it out a couple of times!

Any risk causing sparks around that area, due to petrol vapour?

[MudRunnerTD]

Any risk causing sparks around that area, due to petrol vapour?

Not at all. When I did my quarter cut I did it properly and cut and welded the bottom plate. Lots of guys just simaflex them up! Keep your. Cap on and there should be no risk.

[Parksy]

The tank shouldn't be venting to atmosphere anyway. If you take your filler off and it makes a hissing sound, then all is good and your fuel system is doing what it should be.

[David reeve]

Looks like you did a smick job bud specially for ya first time