Thread: Rear sill repair - lots of pics

I've been systematically going over my NX removing rust, welding where required, then undersealing the whole thing with 2 step Dinitrol. I found the expected rear suspension turret rot which i repaired in the same way as my Sunny GTI by welding 90 degree plates from the inside top of the turret to the wall of the outer arch, but what i wasn't expecting to find is detailed below.

When i removed the left hand side rear sill cover that runs up to the rear wheel arch, things were not good. The outer body skin had corroded away from the seam at the bottom of the sill so i opted to cut it away to investigate further. To give you some idea of the size of the area, this is from the base of the B-Pillar all the way to the rear arch. Aside from the water ingress from the rotted out and absent skin covering the box section, the rear of the box section at the front bottom of the rear arch was also rotten.

I opted to leave the original box section intact rather than cut it out, and use it as a guide to plate over.

You can't beat the NX for contours which make welding a single plate nigh on an impossibility!

I obviously had to reskin the outer shell to finish off, and opted for 0.8mm mild steel which is probably a bit thicker than the original skin (0.5mm) but still easy enough to shape by hand.

Finished product.







I wasn't so fussed about the aesthetic look of it as it's hidden by the plastic cover. I'm just happier that the car is structurally sound again.

So has anyone else found corrosion in this area before, and if so how did you repair it?

Yes that area is very common to rust on these cars. I had a 92 NX2000 auto that I picked up for $300 and the corners where the rockers meet the rear wheel area were completely gone, as in rusted completely off the car. I sold off enough parts to recoup my investment and then gave the shell away for free.

not bad

Another egg saved!

Thanks for all your responses. Corrosion in this area was never really documented on the UK models to date and i found this surprising with mine being a 1995.


Regarding another egg saved, yup, labour of love and looking forward to driving it again!
It's been a driveway ornament for about a week with all the welding, and 3 months in winter storage before that.

any pics of the car fron afar? to see the job?

excellent work so far