Do-it-yourself car door sills repair with mounting foam

In detail: do-it-yourself car door sills repair with mounting foam from a real master for the site my.housecope.com.

It was last year, the car has already been sold.
But somehow I could not get to the computer.
Rotten during the winter, I was very surprised, well, like this, on such machines, anticorrosive is a must.

Well, before the sale, I was offered to slightly improve the appearance =)
the tin is of course complete, a little ashamed even for that, but ... I'm not the first, not the last.

My thresholds were also dented, the wheels were removed while I was on vacation ... and whoever might need stamping with dead tires, well, drunks and drug addicts apparently like these.

As a result: a little gypsum, polyurethane foam, several anti-gravel cans and free silver thresholds =)

Regardless of whether you have a new car or not, sooner or later you have to deal with threshold breakdowns. This problem is caused by the poor quality of roads, a large number of holes, or just a love of extreme driving. It is quite possible to repair thresholds on a car with your own hands: what is needed for this - we will find out further.

Thresholds on a car play several roles at once:

Protect car from mechanical damage, scratches, deformations, etc.
Help passengers when exiting and entering the salon.
Protects body sills.
They are a stylish addition to the car, making it visually more attractive.

Repair of thresholds on a car must be carried out in accordance with the design. It can be different: plastic, metal, chrome, with or without backlighting. Thresholds may or may not be removable, which must also be taken into account during repair work.

For non-removable elements, a special repair technology will be required. Such sills are securely welded to the surface of the car, so you will have to work carefully so as not to damage the surface of the car.

Video (click to play).

To repair the thresholds with your own hands without welding, you will need:

special solution for removing rust;
epoxy adhesive;
solvent;
aluminum powder (silver);
sandpaper;
putty;
fiberglass;
glue brush.

This technology will help to cope with rust even in the deep layers of the threshold and prevent its further spread. First you need to thoroughly remove the rust with a solution. Next - dilute the epoxy resin with silver and hardener and apply to the degreased surface of the threshold. Next, pieces of fiberglass are applied to the glue surface (there should be at least 4-5 pieces), which are then rolled with a rubber roller, for greater bonding to each other.

Now we are waiting for polymerization, which takes about 12 hours. At the final stage of the implementation of this method, it is necessary to grind irregularities, apply a primer, and only then proceed to painting.

Important! Bodywork and sills repair can also be done fiberglass (fiberglass), you can learn more about this technology in the section “Body repair ".

To repair the thresholds of a car with our own hands, we need a base plate (or workbench), a grinder, a welding machine and special tools for straightening. Sometimes a drawing tool can come in handy.

The repair technology is as follows:

If minor repairs are required, then first use a hood to correct unevennessto smooth the surface. To do this, you can use a spotter or an inertial puller.
If a more serious body repair is needed, then you will need to remove the doors and take out the seats. This will prevent damage to them.After that, straightening is performed: in the side of the threshold, a square-shaped window is cut through which the damage is straightened using hydraulic tools, anvils or hoods. When the work is completed, the window can be welded.
Also, the threshold can be welded along the seam where it was welded earlier. In this case, straightening will be done using an anvil.

Be careful when working with welding. Be sure to use special gloves and a face shield.

The amount of work with the thresholds on the Volkswagen Passat B 3 will independently depend on the degree of their damage: sometimes you have to resort to extreme measures and use a partial replacement of a part. Experts give the following recommendations:

It is best not to save on repairs and, if necessary, replace old damaged parts with new ones.
The highest quality repair result will be obtained only with the use of a welding machine.
It is not recommended to use iron and zinc thresholds when replacing: they are not very durable and take a long time to install.

On the market there is a fairly large range of thresholds for body repair of the Passat B3. The best option is to choose strong, close to "native" thresholds, they will last longer and will be convenient to install.During repair work on the thresholds of this model, it is important to consider the following features:

Rotten thresholds need to be replaced with new ones, trying to save on this will be more expensive for yourself in the future.

At the end of the repair work, it is especially important to use an anti-corrosion compound.

For this car model, it is better to choose plastic sills.

In the harsh Russian climate, our cars are constantly exposed to various unfavorable influences, as a result of which a number of troubles arise. One of these is metal corrosion. The first to suffer, as a rule, are the "lower" parts of the body: the bottom, fenders, sills, door arches. In this article I will talk about method of repairing a "rotten" car threshold with your own hands.

Replacing the threshold is not an easy job for a craftsman and not a cheap pleasure for a car enthusiast. Some I had to hear from my clients "Can you somehow do without a replacement?", And there really is a way out, repair of the threshold with fiberglass.

The lower part of the threshold has large metal corrosion centers. It is not possible to repair using welding and patches, we will glue it from fiberglass.

Using a metal drill bit, we clean the area of corrosion and an area of 5-10 cm. Around.

Removal of corrosion.

At this stage, it is necessary to process the corrosion center, this is necessary for better adhesion of materials. We will use a well-known tool called "Rust converter"... It is quite easy to use, you just have to follow the instructions on the product.

We fill in the missing cavities ("matrix", "blank").

To fill the void, you can use various means such as: plasticine, cardboard, polystyrene, wood, etc. In this case, the most optimal and convenient to use is polyurethane foam. Under its weight, the foam tends to "fall off", so you need to prepare in advance for this unpleasant moment. To do this, you need to prepare a stand, all the various tools at hand will do. In my case, it is a wooden board. To facilitate further work, I advise you to cover the stand, for example, with newspapers or film, since it will be quite difficult to separate the foam adhering to the tree.

Before starting to fill the cavities with foam, lightly dampen the surface with a regular garden sprayer. This is necessary for better adhesion to the metal.

We are waiting for the foam to dry.

Using a knife, we cut off the foam and create the most approximate shape of the threshold. For a more accurate removal of the plane, the foam can be leveled with a bar with P40-60 sandpaper.

Working with fiberglass requires some knowledge and a lot of patience. Before starting work with composite materials, it is necessary to protect the body from accidental ingress of resin drops. To do this, I advise you to cover the body with paper or film. The repair surface must be well cleaned and degreased. We dilute the polyester resin in the required amount. Polyester resin is diluted in a ratio of not more than 2% of the catalyst by volume of the resin. Using a brush, saturate the entire surface with resin, then apply glass mat with a density of 300gr / m2. For ease of use, it can be divided into two parts and we get the 150th. This is necessary so that the glass mat does not fall from its weight from the lower part of the threshold, so the build-up of layers should be done gradually, after each layer has dried. Two layers of 300 glass mat will be enough. To insure against "sliding" of all this mass, make some kind of support under the lower part of the threshold. When the resin is dry, the resulting fiberglass must be prepared for the application of the putty. Grinding with coarse abrasive P40-60.

We apply putty.

Absolutely any putty on fiberglass can be applied. If a thicker layer is required to level the surface, then it is better to use a filler with fiberglass, then universal or with an aluminum filler. After leveling the surface, it is necessary to prime it, apply an anti-gravel coating on top of the soil and paint.

This method can repair not only the thresholds of the carbut also arches, fenders, doors and more. All this, of course, is not durable, approximately the service life of such a structure ranges from 2-5 years, of course it still depends on the quality of the master.

Repair of car thresholds today is rightfully included in the list of works that every car owner should be able to perform. Knowing how to repair these car parts with his own hands, the driver has the opportunity to save a decent amount of money. Let's find out about the principles of repair and what tools are needed for this.

Thresholds are an integral part of the body of any modern car. Due to their location in the car, these elements are among the first to succumb to moisture and substances that are sprayed on the road surface. In addition, the thresholds are severely damaged from stones flying out from under the front wheels of the car. This happens especially often when the driver made a mistake with the choice of the type of mud flaps for the car.

Fortunately, it is not so difficult to repair body parts with your own hands. The main thing is to prepare tools and understand the principle of repairing these auto elements. How the repair of automobile thresholds will be carried out directly depends on the type of parts. All elements lend themselves to classification based on the method of attaching them to the body and their purpose.According to these features, the parts are divided into removable, non-removable and power thresholds.. The first type includes parts that are attached to the car body using self-tapping screws or special bolts.

They play the role of a step for a comfortable fit in the car, and also perform a protective function - they prevent stones from falling on the doors. The thresholds of the second type are attached to the machine by welding. Their presence makes the car body more rigid. Power elements are an integral part of SUVs with a frame body. They can be attached to the machine either by welding or by large special bolts. The cross-section of such parts is several times larger than in the thresholds on cars with monocoque bodies.

After you have determined what type of parts are on your car, you can start repairing them yourself. First of all, we will consider the restoration of removable thresholds, since it is the details of this type that are considered the most popular on the market.

Detachable parts are susceptible to dirt and damage as a result of human exposure. Since these thresholds are mainly used for embarking and disembarking passengers, they are located almost on the same level with the floor of the passenger compartment. In fact, such details can be considered an additional element of the interior. Due to the location of the parts, stones and moisture rarely get on them. Another thing is removable sills designed for installation outside the body. Image - Do-it-yourself car door sills repair with foam

They bulge a little, making the car wider, and are installed much lower than the passenger compartment. In this regard, they can be damaged not only by humans, but also by large cobblestones, rust, or as a result of careless parking. Removable thresholds are easy to do-it-yourself restoration. Repairs are usually done with a conventional anvil, workbench and mallet. Other tools are used to repair steel parts as needed. Although the thresholds are made of metal, they must be handled with extreme caution. If you do the job correctly and accurately, you will be able to avoid the need to re-paint the sills of the car.

The most common problem with both internal and external removable elements is the appearance of dents. To eliminate them, you will have to apply alignment. For this purpose, the part is mounted on a workbench and then leveled with a hammer. Depending on the degree of damage, the part may require re-painting. Another common problem is rust formation. It is characteristic of thresholds installed on the outside of the car, however, in regions with frequent precipitation, internal thresholds can also rust.

If the corrosion has not managed to damage too much of the part, then the affected area can be cut off, and a metal patch can be welded on instead. If rust has damaged most of it, then, in view of saving time and effort, it is best to completely replace the part with a new element.

The most common damage to these elements is considered to be corrosion and dents due to prolonged use in poor conditions. Corrosion occurs on thresholds as a result of the regular ingress of water, various saline solutions and chemicals. Corrosion develops especially quickly due to the poor quality of the factory painting of parts. This is especially true for domestic cars.In addition to moisture, thresholds are also negatively affected by cobblestones. When flying out from under the wheels, they form noticeable dents. Moreover, even the driver himself can damage this part of the body of his car by improperly installing the jack in the process of changing wheels. Whatever the damage to non-removable thresholds, before proceeding with their restoration with your own hands, it is worth assessing the degree of damage to the parts. The list of tools required for repair directly depends on the latter. Image - Do-it-yourself car door sills repair with foam

To eliminate breakdowns of small and medium severity, you may need:

Workbench;
welding machine or spotter;
manual hood;
repair support;
anvils;
Bulgarian;
locksmith tools.

Having all these tools, you can start repairing. In order to fix dents or remove skewed thresholds, you can use a manual hood and spotter. These tools make it possible not to disconnect the body element, but to make repairs on site. To do this, special loops are attached to the sill body, for which the spotter pulls out the body part, returning it to its previous shape.

If you cannot get rid of dents using these methods, then the threshold needs to be repaired by welding. To do this, a rectangular hole must be cut in the side of the part. An anvil must be inserted into it, after which the dents are straightened by tapping on the surface of the thresholds with a straightening hammer. If the damage to the thresholds is much more serious, then cuts must be made in several places of the parts for repair. After repair, the incised parts are closed with patches.

It should be noted that the restoration of thresholds without the need for welding is considered very popular today. In this case, the driver will repair the irregularities on the surface of the part with epoxy glue or fiberglass.

Depending on the degree of damage, the restoration of parts on powerful SUVs can be done either by hand or in a workshop. Since in most cases damage occurs from impacts against large stones, the thresholds need to be repaired exclusively by welding. To do this, the part is dismantled from the machine, and the standard holes for fasteners are closed with metal bushings. After that, you need to make new holes and proceed directly to repairing the damaged part.Welding the upper part of the old threshold with a new metal lining is considered the most effective. First, the part is leveled and cleaned from the remnants of the old lining. The top of the sill needs to be perfectly clean, so be prepared for a lot of time. After that, a new panel is welded to the standard pad. The finished part must be cleaned of dust and painted.

There is also now a link to a complete renovation of thresholds and floors. This is 5 videos for 50 minutes. Even if you do not repair the entire thresholds, you can see something about the repair, how to cut, how to drill, how to adjust, and more.
These videos are at the link

Sooner or later, many motorists have to resort to repairing car thresholds, especially those who have not new cars on the maintenance.

The quality of Russian roads is still not ideal, and when it will be so, the question is rhetorical.

A huge number of pits can render the car unusable, and after a few years seriously shake the nerves of the owner.

At the same time, the thresholds of the car, the bottom of the doors and the arches suffer most from such extreme driving.

Naturally, even the first signs of corrosion cannot be triggered and action must be taken immediately. If there is no desire to do the repair of thresholds with your own hands, then it is better to contact a specialist.

Today, there are two main types of thresholds - welded to the base or removable.

Removable sills are attached to the side and outside of the side members. Their main purpose is to protect the lower part of the car from small stones flying out from under the wheels.

Welded thresholds are more common. In fact, they merge with the underbody, giving it an extra level of rigidity.

Most often, removable thresholds are made of metal (less often of plastic). Fastening is carried out using self-tapping screws.

It is very easy to repair them. It is necessary to carefully remove the product by unscrewing the screws and restore the threshold with a small hammer (if we are talking about a metal product).

After that, the threshold must be covered with a special anti-corrosion compound to prevent the appearance of rust.

There are situations when the repair of removable thresholds is useless (for example, when the material has already completely rotted).

It is better to completely replace the old threshold with a new one. This will ultimately come out much cheaper.

Such a threshold is part of the structure, therefore, the repair must be carried out according to a different scenario.

If the damage is minor, straightening is done from the outside. If there are small dents, it is necessary to drill a small hole in the threshold and straighten the problem area using special tools.

Tool for pulling out dents.

Another option is to carefully cover the damaged area with small steel patches. Any competent tinsmith can easily cope with such work.

Dents in thresholds can be repaired with a steel bar that is welded to the damaged part and then pulled out using hand force or a special winch. Once the work is complete, the rod can be cut off.

In case of moderate damage, the seats and doors will have to be removed. Otherwise, the latter will interfere with the performance of high-quality repairs.

Areas with the largest damage should be replaced. These include:

Through holes;
Deep dents;
Torn off parts and so on.

This area can be cut out with a grinder and welded on a metal structure of appropriate dimensions.

Today, there are two main methods of straightening car thresholds.

In the first method, a rectangular window is cut into which the anvil is inserted.

This method allows the affected area to be tightened using hydraulic or mechanical devices.

Once the problem spot is fixed, the cut window can be welded neatly. Tin solder can be used to straighten the seam.

In the second method, the so-called transverse cuts are used, which are made in the surface of the threshold.

The weld points are disconnected, an anvil is inserted (preferably small) and the damaged area is straightened.

Welding is carried out only after straightening the surface. If the area directly under the door is damaged, then it must be cut out and replaced with a similar one.

If the rack is also damaged with the threshold, then it is necessary to simultaneously replace the threshold and the rack. It is necessary to act according to a simple scheme.

First, the B-pillar spar must be cut. Before you start straightening the spar, you need to make sure that the car body is strong.

After that, the installation site should be cleaned, and all excess metal parts removed.

Further, the surface of the side member must be leveled and adjusted.After that, fastening, installation and welding are performed. That's all. It remains to put the doors in place and adjust the gaps.

There are two main processing methods.

The first method involves the use of auto chemistry (mastic, special varnish or impregnation).

This method is most effective when working in a garage. But there are also negative aspects - the purchase of expensive materials is required to carry out the work.

In some cases, you can use cheap products, but they are not suitable for all foreign cars.

The second way is electrochemical protection. This treatment must be carried out exclusively by an automotive workshop where you can expect to receive a warranty.

The peculiarity of this protection lies in the fact that special electrodes are mounted on the threshold, to which a direct current is supplied.

These products pull corrosion on themselves, and not on thresholds. The term of such protection is about one year. As for the cold season, the electrodes will last a much shorter period - about three months.

In some services, ordinary plastic door sills are installed, which have a more affordable price and are easy to change.

These pads reliably protect thresholds from dirt and stones, but do not protect against corrosion, which "gets" under them.

Therefore, if you really put such a pad, then only after anti-corrosion treatment.

Video (click to play).