944 Rust areas

[OlberJ]

Any 944 experts on here?

Started welding up my mates 944 at the weekend, new inner and outer sills, rear triangles and new sections for the outer edge floor pans.

Any other particularly bad areas we should be looking at?


Cheers,
Olie

[pauljmcnulty]

Front wing bottoms, battery tray if it's an early one, spare wheel well, rear hatch pin area, around windscreen if it's had a bodged replacement, and both rear cubby holes. Think that's it!

Obviously the sills and associated areas are most important, but I heard the outer sills were out of stock ATM?

[tr7v8]

Rear number plate area, including rear light apertures, & number plate holes.

[OlberJ]

Perfect, I'll add them to the list for .

Did notice the front wing rear bottoms were rusted, should patch up fine though.

He got sill panels from somebody in Kilmarnock I believe. They're not factory but the shape and fit look pretty good when welded on. Only needed a little trimming to the inner sill.

[NJH]

If your really unlucky the area where the floor meets the bulk head can rust out. Literally the whole floor could need replacing but this seems to be extremely rare, I have only seen of it twice, once on a car I got some parts from and once on a car being prepped for the track. Have the rear quarter wheel arch lips been mentioned? This seems fairly common but really doesn't matter much to have a bit of rust back there.

Something I have relayed on the forums many times was seeing my own S2 body shell after it had been through the acid dip. Before hand it had pretty bad looking rust on the sills and the front wing bottoms. After the dip literally all that needed replacing was 2 areas the size of your fist where the sill meets the rear quarter and of course the wings were scrap which didn't matter as they were replaced with fibreglass. The rest of the shell looked perfect.

[OlberJ]

It has had work and paint before so the rear arches and most of the external car is looking rather good. It's mainly the sills that need done to make the under match the outer but i may as well check the lot while it's up on stands.

Thanks for the tips folk, appreciated.

[pauljmcnulty]

Please give us some feedback on the pattern sills? The Porsche ones are a perfect fit, and were cheap before they went out of stock, so it's been a no-brainer to recommend them. If, as often happens, the limited new production is a lot more expensive, then fettling pattern sills to fit might be the better option.

[NJH]

ISTR they are HT steel, as long as pattern replacements are the same quality steel otherwise I think it would be better to pay the money for original panels.

[OlberJ]

Inner sills are folded flat sections, no holes like the original. As mentioned, a little trimming needed to the top to fit right (couple of mm)

Outers look pretty spot on.