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Rotten Sill
#1
Has anyone here repaired a sill on a Berlingo?

I'm about to start cutting and welding up the offside sill which has rotted due to a blocked drain hole and the last owner not using the jacking point!

Repair looks reasonably easy, just wondered if anyone has any photos of similar work they've done.

Thanks!

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#2
I've done plenty of sills on different cars but never seen a Berlingo with rot. Look on mig welding forum for inspiration there will be something similar to your job. Just make sure to cut out all the rot back to good metal before you start making a template for your repair piece unless you are replacing the whole section with a purchased panel. Anything you cut out should be seam welded if it is an insert but the bottom flange can be plug (button) welded for appearance to look standard.
So where does this bit go then ?
[-] The following 1 user says Thank You to ffrenchie for this post:
  • bengy1975
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#3
Like ffrenchie ive never seen a Berlingo with a rotten sill may be it was damaged at some time an the corrosion set in?

Maybe the Citroen forum may help on this one? have you done a search?
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#4
At least with a Berlingo you won't get rot spreading ......

Many years ago my son came home with a Metro car and asked if I could put a new sill on it for him, to cut a long story short I ended up putting in two full sill panels, three quarters of a door pillar and used most of an 8x4 foot sheet of steel making a new floor and patching other bits !!!

Once you've done your repairs make sure you flood the internals with something like Dinitrol for lasting protection ( like waxoyl but better ) and you'll not have the pleasure of doing it all again in a couple of short years.
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#5
(28-11-2018, 09:04 AM)ffrenchie Wrote:  I've done plenty of sills on different cars but never seen a Berlingo with rot. Look on mig welding forum for inspiration there will be something similar to your job. Just make sure to cut out all the rot back to good metal before you start making a template for your repair piece unless you are replacing the whole section with a purchased panel. Anything you cut out should be seam welded if it is an insert but the bottom flange can be plug (button) welded for appearance to look standard.
Thanks for your reply.

I'm a member on the Mig Forum, it's a great place for information!

Can you tell me if the Berlingo is galvanised?

Need to make sure I clean it well enough if it is.

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#6
No galvanised sections on the old Berlingo and no need to worry too much even if there are unless you have your head in a bag with the weld. Fumes will dissipate if you are in an open area big enough to house the vehicle.
So where does this bit go then ?
[-] The following 1 user says Thank You to ffrenchie for this post:
  • bengy1975
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