Duetto Sills

beatle_bayly · #1 (**permalink**) 04-21-2004, 05:58 AM

Against my better judgement I have begun the trek of discovery into the sills of my RHD '67.

I removed the LH front splash guard at the rear of the wheelwell and dutifully removed about a pint of dirt and rusted metal ! My intention is to clean out both ends of both sills, determine the damage, then if it's not too bad I'll spray in some preventative goo (fishoil) and start saving $$ for repairs.
So far the front of the lower sill looks pretty bad, at least what's left of it, but the rest of the metal in the area looks remarkably good. I suspect that the sill centre sections were replaced at some time, but the ends are now in need of attention, mainly from POs efforts to seal the splashguards. All this achieved is to create a moisture and dirt trap.

So, I would like to cut a few holes in the top of the sills for inspection, cleaning and treating purposes. I have a diagram of the X-section of a sill (http://www.alfaparts.net/105_115sill.htm#) but am wondering if anyone knows the location of the 'gussets' welded into the inner sill ? I am thinking of cutting a 1" dia hole at both ends of the inboard sill (marked 2 in the pic below) and possibly some smaller holes in the outboard portion (marked 1 in pic below). I will blank the holes with glued-in grommets and the evidence will be covered by the sill trim.

What I don't want to do is cut into any of the gussets.

Comments are welcome on the stupidity of my plan and I will upload pics of the rusty areas to the site in the signature block below.

**ossodiseppia** · #2 (**permalink**) 04-21-2004, 07:58 AM

Most often, it's the leading and trailing ends of the inner sills that rust. In severe cases, the center section rusts. When this happens, it can make the car a little on the unsafe ride. If you have a friend that has one of those scopes on a flexible tube(not sure of the technical term), you could inspect the inner and outter sills with that. Maybe you could rent one.

beatle_bayly · #3 (**permalink**) 04-22-2004, 06:04 AM

Thanks Osso.
Believe it or not I use a borescope (aka endoscope, videoscope etc) in my work. I will be taking a look inside with one and even taking a video record. The main reason for the holes is to blow the crud fore and aft and out of the sill. At present my probing just seems to be forcing the crud into the centre.

OK then, looks like I'll be a pioneer......cover me 'cause I'm goin in !!!

**ossodiseppia** · #4 (**permalink**) 04-22-2004, 07:28 AM

That's cool. Can you get some still photos from it as well? Cutting all of those holes seems like a lot of work. I wonder if you could blast it with air? You could put a long extension on an air hose and then blast the crap out of it. I assume that we are talking about lose rust that has gotten inside the frame rails?

**Roadtrip** · #5 (**permalink**) 04-22-2004, 08:03 AM

"Believe it or not I use a borescope (aka endoscope, videoscope etc) in my work."

It's ok to admit you're a proctologist, Beatle. You're among friends

Seriously, though, have you thought about making a simple hook out of air pipe and a nozzle? That way you could blow the debrie back instead of farther in.

duettogmw · #6 (**permalink**) 04-22-2004, 03:23 PM

Hi Paul
I have the entire side of my Duetto open and will that a photo. The cars
being restored in Brisbane $$$. I know your looking for parts ,I have some.
My emails gregward@swiftdsl.com.au

Greg

Bill77 · #7 (**permalink**) 04-22-2004, 06:37 PM

Beatle Bayly & Greg,

Please post photos of the rocker areas. This will be helpful to many BB Members, including me.

I just poked a screwdriver through a very small rust spot on the passenger rocker.

beatle_bayly · #8 (**permalink**) 04-23-2004, 02:45 AM

OSSO: Yep, should be able to get stills of the sills. The idea was to cut only two largish holes for access, with either a holesaw or a step-drill. I'll need holes to scope the area anyway, won't I ? I guess if both ends of the sills are rusted I just access the innards thru there.

JOHN S: I'm not a proctologist.......but I'll look into it for ya !!! I willl use a combination of vacuum and pressure attachments, brushes, screwdrivers, wire and anything else I can think of.

GREG: I would LOVE pics. Take as many as you dare and send them. Im at dabaylys@bigpond.net.au. You don't have two spare eyeball dash vent 'valves' do you ? The part which has the lever under the dash to open/close the vent. PO has obviously misplaced mine during a prior resto and replaced them with plastic drinking cups with the bottoms cut out !!!!!!!!!!!!!!!!!

**ossodiseppia** · #9 (**permalink**) 04-23-2004, 08:07 AM

I would put the holes at either/both ends from inside the wheel wells. We have companies here in the US that "rust proof" cars by drilling holes in the same locations and then spraying in some sort of sealant. They have special wands the they can put in the holes to apply the rust proofing. I am just a little reluctant to put holes anywhere else but the ends. I may be too cautious, though.