Classic Mini Workshop - Project Sprout Pt.15 - Inner Sill Repairs

Please consider subscribing to keep up to date with the latest videos and content. Thank you for the likes and comments, it is greatly appreciated.
Find me on Facebook / classicminiws
Here it is, the new project Mini. Found on E-bay but I lost the auction only to later find the higher bidder messed the seller around so it was offered to the next highest bidder...... Me. The Mini is a 1997 Rover Cooper MPI and has been off the road in a garage since 2007! It's what some might call a barn find.
In this update I cut the rust out of the inner sill, make a template then size and cut the replacement metal to an almost perfect fit. I then mig weld the repair sections in place using a butt welded seam.
I found the existing sound proofing / deadening was not fluch with the floor and a gap existed between the two so I removed all of the old sound proofing using a hammer, chisel, scraper, screwdriver and some paint thinners to finish off.

[@oliveirainvestments2884]

Great job mate... learn a lot from you!!! Big hug from Spain 🇪🇸...!

[@classicminiworkshop]

Awesome, thank you!

[@markharris7662]

Looking better already. Saved just in time i think.

[@DBMiniDIY]

I remember spending a day removing that sound deadening and agree what s horrible job to do, nice repairs and the floor looks in great condition

[@SimpsonsClassics]

Great video Keith I agree with the seam weld methods if there isn’t area for damp that’s a job well done and looks more correct to the sill. Nice work buddy 👍

[@LoneStarMini]

that was good to see even you blow holes and I love the copper pipe homemade tool.. love watching your skill...

[@classicminiworkshop]

Cheers Randy, the copper pipe trick is really handy

[@phillthrift3095]

New follower here, great work and nice to see some brilliant tips such as using copper behind 👍 looking forward to the next installment, picking up my rusty 1987 soon, first one I've owned since the early '90s! I love a good project

[@MegaDyte]

Tip for removing soundproofing, I used plumbers freeze spray and a rubber mallet works great

[@markdraper7]

Lovely tidy repairs and welding as usual! Maybe one day i'll stop blowing holes and be able to weld as good as you.

[@peterhulmston9046]

Nice to see a great job, keep up the good work 👍

[@johnkinnane547]

G’day and greetings from Tasmania Australia 🇦🇺, I just happened to stumble across your channel and that was it I have subscribed I once had a mini I restored, would love to do another one some day. Really enjoyed going over your previous videos and look forward to watching more thank you kind regards John

[@classicminiworkshop]

Thanks John, glad you enjoy the videos

[@BMCWorkshop]

Great Video Corn Beef, that floor looks mint mate and love your welding. I have the 135te too which is a great welder but I'm thinking of upgrading it now

[@soulboy0506]

Looking good Keith, I will be taking PUD to the body shop to get a quote to do the sill over the next few weeks........

[@classicminiworkshop]

Cool, it will be interesting to see what the going rate is nowadays

[@soulboy0506]

@@classicminiworkshop Eye watering I expect lol

[@robertnehrbass2755]

Great video,would have liked to see more of you pounding out the floor.I remember seeing davejaguar66 doing his mini with wood and bolts on both side.My floor needs some pulling or hammering done .

[@Xpp.]

Nice neat repairs !!

[@nielsandersen8779]

Nice work👍

[@Boro-Lineman]

I use heat gun and wallpaper scraper to take it out then thinners to clean up the panel

[@sam._.buswell8181]

Tell you what Keith sprout is coming along well ! And I know it’s a bit of a faf but next time you go to remove the sound deadening on the floor on any car you could try what I did, I used dry ice and this freezes the material solid so with a dead weight hammer it comes up super easy and it becomes an easy job.

[@classicminiworkshop]

Wish I could get some dry ice, I'm sure it would work really well. The other side is soft so I reckon it will be a nightmare to remove

[@Peakwanderer]

@@classicminiworkshop I've seen this stuff (or similar) used with very good results www.screwfix.com/p/rothenberger-quick-freeze-pipe-freezing-spray-500g/95943

[@chrisdowns9828]

Nice repairs. I have a 135TE also, what settings were you using for the 0.8mm steel? Cheers.

[@classicminiworkshop]

1 Max and 6 to 7 wire speed

[@chrisdowns9828]

Classic Mini Workshop brilliant, thanks for quick reply. Got some welding to do on my Mayfair. Cheers.

[@midgelambert3880]

I noticed the little square hole in the sill just above your patch. Is that access to spray waxoyl or some similar fluid into the sill? Did that come from the factory like that? If I was to drill a hole on the inner side of the sill like that would it compromise the strength of the sill?

[@classicminiworkshop]

Yes there are 2 square holes, one in the front and one in the back. I assume they are for rust proofing

[@michaelflood4535]

Hi Keith you made a lovely job of that as usual take your time and it comes out good, would you say the Clarke 135 TE is a good welder for this type of work as looking a getting that model myself.

[@classicminiworkshop]

Yes, it's fine for most stuff on a Mini. I might consider the 151TE if you need to do some heavier stuff

[@23GJ84]

👍🏻

[@moran68]

Great video ,can I ask what's the plan with sprout when it's finished are you keeping her or selling her on ?

[@classicminiworkshop]

I will be selling it, unless I get too attached to it LOL. I will probably use it for the show season next year and sell it at the end

[@baylisskid]

Nice welding for start of the season. What welder do you have I’m just looking at buying one and not sure wether to spend a lot or go mid range or what?

[@classicminiworkshop]

Mine is a Clarke 135TE, it's been perfect for the bits I do

[@baylisskid]

Classic Mini Workshop thanks appreciate the replies. Also which primer do you use? There’s so many mixed views online as to which is the best. My plan is to get mine on the spit jig and fully weld and prep and send away for painting.

[@classicminiworkshop]

@@baylisskid Hi I use Upol Etch or Weld through

[@samscorner6111]

Awesome minis! Subscribed! Come check out our channel and Japan’s minis scene! Thanks for your support