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Old 11-29-2011, 01:27 PM   #1
SRGW
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1997 SL1
Thumbs Up 1995 Sl1 door sill repair

As you can see I have the Saturn door sill rot problem on my 1995 Sl1. This is the passenger side the drivers side is slightly rusted and is still solid. Sorry I did not take a picture of the replacement panel but it was from Home Depot, a 12" by 18" aluminum sheet metal panel which I bent and cut to size. Step 1. Removed all trim from sill and didn't think it was THAT BAD!!! Step 2. Tried to cut away as much rusted metal as possible.(the channel/box below this was not rusted). Step 3.Wire wheeled/brushed entire area and Sprayed entire area with Rust Reformer by Rust-oleum. Step 4. Fitted metal panel and secured it with JB weld, let dry overnight. Step 5. Put a coat of Bondo over the entire area, sanded and painted it with Rust Reformer. Put black silicone RTV along space below rubber moulding and body panel. Reinstalled all trim. (note I cut off the mounting pins/tabs on the step plate trim and adhered and sealed it with silicone RTV.

1995 SL1 186,250 and go'in strong!!
CHECK YOUR OIL!!!
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Old 11-29-2011, 02:23 PM   #2
madpogue
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1996 SW2
Default Re: 1995 Sl1 door sill repair

Gotta wonder how long that JB Weld will hold, with dissimilar metals and different coefficients of expansion. Also, you have done nothing for it structurally.
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Old 11-29-2011, 02:23 PM   #3
mattelderca
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1998 SC1
1996 SL
Default Re: 1995 Sl1 door sill repair

That is ok for a non structural coverup, but remember, that is the cars frame your working on.
...
2000 SL1 freebie, my sons DD
1998 SC1 still running, FOR SALE cheap!
1996 SL, GONE but not forgotten
2005 Generic Silver Minivan (Kia Sedona)
2009 Nissan Sentra 2.0S
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Old 11-29-2011, 04:21 PM   #4
spacemanspif
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1995 SL2
Default Re: 1995 Sl1 door sill repair

I've often wondered about that area and what kind of structural service it provides. My 95 has small(ish) rust problems in the same spot, I cut the tabs off the sill plates a while ago and kind of pried them up so that they don't hold water as much any more.

Always wondered if I could just clean the holes and leave them open or if I should get some material out of a junk yard and weld in a patch. Might be a fun learning project but would rather not do it at all lol.

Anyone know how much integrity is actually lost by holes in the area pictured by the OP??
...
-Mike

1995 SL2 5spd - Stock/MP2 trans swap - 258,XXX miles - 38mpg @ 65mph
1987 Monte Carlo SS - 5.3/4L80E swap - 13.92@103mph - 19mpg @65mph - needs POSI
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