Getting a good fit with patch panels, what are your methods?

[BenMig150]

Hi guys,

It's been a while since I have been on this forum, I am currently in the process of repairing rusted sills on my Mk5 VW Golf, its just the rear section of both sills that began to rust through so I'm wanting to sort it out before it spreads and I'm having to put whole sill panels on it.

Anyway I want to try and do the best job I can of it as it is otherwise a nice clean car and I'd like to keep it looking presentable. The problem I'm having is figuring out a way to cut my sill panel to fit the hole well. (I bought pre fabricated sills to make the job a bit easier hopefully) usually I'm used to making cardboard templates but I'm finding it very difficult as the sill bends underneath the car and around at the wheel arch end in quite an awkward shape to be able to copy with carboard, also when cutting out the rust I ended up having to chop 4 pieces out as the rust kept going further back inside the sill.. like it always does! so the pieces I cut out aren't very accurate to try and use as a template either.

How would you go about it? I have thought of maybe cutting the sill piece slightly larger than the hole and then marking the car and cutting a bit more out but I'm a bit reluctant to chop anymore out of it due to being quite close to the paintwork, currently the repair is underneath the rubberized coating so it will be easier to cover up after welding rather than having to get the rear quarters painted.

I look forward to hearing any suggestions.

Thanks

 

[p0689109]

So you have the complete sills. I would cut the old one/s out whole and fit new whole as it is difficult to ensure all the rust is removed and time wise it would probably be the same, no fiddling ensuring the patch is accurate etc

 

[Myles1970]

Photos might help..... But I tend to use masking tape, tape it onto the sections that I've cut out, minimum two layers of tape. Then stick the tape onto some fresh metal and cut around it using whatever method suits... Alternatively, start with the tape on the hole if the piece you've cut out have disintegrated.

Check out Make It Kustom on YT for a better explanation

 

[tom2207]

So you have the complete sills. I would cut the old one/s out whole and fit new whole as it is difficult to ensure all the rust is removed and time wise it would probably be the same, no fiddling ensuring the patch is accurate etc

depends how good the replacement pattern parts are , and how good the rest of the sill is , careful cleaning and a really good look is the best starting point .... then cut the new panel bigger than you think you need it , and I trim the sound bit of the old panel to fit the new bit , way easier that way round.

 

[striker]

Check out YouTube. Fitzees fabrications has a few good tips for patch panels...here's just one

 

[ajlelectronics]

The way I did it is to cut a repair panel from the new sill, cut away the worst of the old one and then offer it up for marking around. Then cut out to suit. Scorpio sill repair

 

[BenMig150]

Thanks guys, managed to cut it to the right size in the end with a combination of measurements from the old cut out pieces and cardboard template. Fits pretty good after a lot of fiddling around bending it into shape. Not the best matching sill panel! Anyways just have to weld it on now then move on to the other side.

 

[p0689109]

Now the hard bit then. Getting it welded in and ground flat so that it looks original. Best of luck and merry xmas.

 

[BenMig150]

Yeah made a start on it today and tacked it in place, will do a bit more tomorrow, taking my time as it’s been a while since I’ve done any welding. Hopefully it goes OK.. luckily I’ve got another car to drive over winter as I’m far from the fastest welder ha ha.. Merry Christmas to you too.

 

[p0689109]

Better to take your time as the thin panels need patience to ensure no blow through. Best of luck and have a good weekend.

 

[Onoff]

Yeah made a start on it today and tacked it in place, will do a bit more tomorrow, taking my time as it’s been a while since I’ve done any welding. Hopefully it goes OK.. luckily I’ve got another car to drive over winter as I’m far from the fastest welder ha ha.. Merry Christmas to you too.

Progress pictures are always good!

 

[BenMig150]

Got it welded in today and mostly ground down, need to go back and fill in a hole I burnt just on the underside of the sill, overall I’m happy with how it’s gone though, needs a little bit more finishing off and maybe a few pinholes filling but I’ll get back to it after Christmas then on to the other side before stone chip and paint.

 

[stichill99]

That looks really good work.

 

[BenMig150]

That looks really good work.

Thank you, still not finished it yet just chopped out the rust on the other side. Ended up catching covid after Christmas so that’s slowed me down. Hopefully I can get it finished and back on the road this month. Might upload some more photos once I’ve started welding in the drivers side.

 

[BenMig150]

Got this bit done inside the wheel arch this evening welded on and ground down, bit of an awkward shape to make but it’s done now, just the last piece of the outside sill to cut to size and weld on and I’ll be done welding!

 

[BenMig150]

Thought I would add a last update to this for anyone that’s interested, I’m glad to say I’ve welded the last piece on today and finished it. Not much warping at all which I’m l pretty happy with so now on to stonechip and paint before I can finally drive my car again.. just managed to get it done before running out of gas!

Anyway this is my last update I won’t bore you all with photos of stonechip, I just wanted to show my work because my girlfriend isn’t interested.. lol!

 

[stichill99]

Yup I am interested.Lets see what the finished product is like. Looks top notch up to now!

 

[p0689109]

Ditto. Well done.

 

[BenMig150]

Well guys it’s all done, seam sealed inside and out, stonechipped, painted, lacquered, cavity waxed.

Pretty happy with it, you can see a very slight difference in the stone chip texture if you get on the floor and inspect it, I guess I could have stone chipped the whole sills both sides but you have to cut the line somewhere it’s not a show car it’s a daily driver lol.

But overall I’m very pleased with it and it will hopefully give me a few more years out of the car.

The white bits above the stonechip are just masking tape residue which I need to remove but I’m leaving car for about a week to let everything cure as I think the paints still slightly soft at the moment so I don’t want to damage it.

I’m just relieved it’s all done now, the Peugeot 207 GTi I’ve been driving whilst it’s been off the road has been the most unreliable thing ever!

 

[Myles1970]

Top quality job!