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Projects and Restorations Building a car from scratch, restoring your pride and joy, building a track car, or starting a long term project? This is your place to document it.

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Old 08-07-2016, 11:10 PM   #11
Mikej857
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Mine was exactly the same, check inside the arches behind the liners there are some sponge packing that just sucks up the water and rots the ends of the sills away.

It's ridiculous that a car that's only 13 years old can rot so badly
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Old 09-07-2016, 12:56 AM   #12
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Mine was exactly the same, check inside the arches behind the liners there are some sponge packing that just sucks up the water and rots the ends of the sills away.

It's ridiculous that a car that's only 13 years old can rot so badly


I've already had the passenger side rear arch liner off and just like you said the end of the sill is rotten.
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Old 09-07-2016, 03:26 PM   #13
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Gutted for you that the bumper was so badly damaged, your doing some good repairs though! My FRS was rusty as well, had to sell it as couldnt afford it after buying a house. Keep up the good work though!
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Old 09-07-2016, 03:43 PM   #14
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Jeepers I never realised these were such rot boxes. My (now)28 year old 205 GTI had less rust on it when I did the resto 4 years ago!!

Either way hats off will be clean when it's done.


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Old 10-07-2016, 06:51 PM   #15
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Update on the sills. I started on the drivers side which I thought was original. Turns out there was so much surface rust it was hiding the evidence this sill had also been replaced. Here's some pics.



The metal cleaned up nicely. But upon further inspection it turns out the original sill has not been cut out and the replacement sill has just been welded on top of the old one😠.

This obviously is causing a moisture trap so I'll probably have to have the sills replaced. I'll make sure its done properly this time!

Last edited by Ford8loke; 10-07-2016 at 06:53 PM.
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Old 10-07-2016, 07:21 PM   #16
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Might of had a accident
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Old 10-07-2016, 10:37 PM   #17
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Might of had a accident


Don't think its been stacked, both sides are the same. I've owned accident damaged cars before and there's usually a give away like panel gaps and different aged components from one side to the other.
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Old 13-07-2016, 10:36 AM   #18
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wow, thats shocking! lovely cars but that welding looks nasty. i cannot beleive how crusty these are. great to see its getting the TLC it deserves. a neighbour of mine has one with 33k and FFSH, i was tempted to buy it as he has mk2 rs2000 low miler and his wife wants him to sell the Mk1 RS. just goes to show you what can be lurking behind sills etc.

good luck!
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Old 13-07-2016, 11:29 AM   #19
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I think its safe to say the car is in better hands now than it was!
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Old 13-07-2016, 11:34 AM   #20
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That's some shocking welding but it's obviously been done that way as it's covered by the body kit and from what I've seen its the norm and there are far worse out there.

I saw one a couple of weeks ago that was having some "rust repair" where the owner had said he couldn't afford to have the rust on the arches cut out and replaced (anpther area prone to rusting is the o/s rear arch) so they simply filled it full of filler so in 6 months time it'll just bubble through again totally pointless to me.

Your doing what plenty of people would dread uncovering horrors under hidden trims
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