Volvo 240 - Rotten Sills Part 1

The sills are by far the worst part of this project car, so lets cut them out and see what we find!
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[@hedlund88]

Bit late but the cowl vents drains through the sills , there for all the leaves :)

[@RichardJones-rp1sm]

Great video Steve, keep up the good work

[@Mark1405Leeds]

👍 You have the endless patience needed for this kind of job! I'd be so frustrated I'd scrap it and buy a good one!

[@StevesMachines]

Other than a few patches and some missed maintenance this one is one of the better ones I've seen.

[@blacksoulwolf3391]

Well never thought I'd land here, but keep up the good work mate

[@PaulinesPastimes]

Wow, it's in quite good condition really. I have seen so many videos showing the damage that salted roads can cause and this car doesn't appear to have been attacked as much as I expected. Obviously well built and factory rust proofed. I hope it turns out well. 😊✔

[@StevesMachines]

Yes ots much better than I expected, rust is quite the killer of cars in the UK. I'm amazed the inner sills are so good, fingers crossed the other side is the same.

[@mikenewman137]

Great work Steve, i do like an old Volvo, it does look a nice a car.

[@StevesMachines]

Cheers, other than the sills it does seem to be in good shape.

[@Zeem4]

Yay, rotten sills! I cut "investigatory" holes in mine back in August, and all I've done since then is poke and prod at them, occasionally staring at them to work out how the hell I can fix it.

[@StevesMachines]

Is it just your outer sills or has your inners and floor gone too?

[@Zeem4]

@@StevesMachines The floor's OK - it's a Peugeot Expert so I think the depth of the sills has helped. I've only properly investigated the driver's side (which is rustier than the passenger side for some reason), but the outer, middle and inner sills are rotten in various places along the whole length - but especially at the front, where the bottom of the A-pillar is also missing. Only the outers are available so I need to fabricate the rest. The project is massively bigger than anything I've attempted before, but I keep watching channels like this one and Cold War Motors for inspiration and ideas!

[@StevesMachines]

I watch quite a few channels for similar reasons 😀 Good luck

[@terryatkinson3182]

@alextaylor give it a go, what's the worst that could happen.... apart from fire or bigger holes 🤔

[@StevesMachines]

I rarely know what I'm doing til I start 😆

[@kja1888]

If I recall correctly from my college days if you're replacing factory spot welds with MiG plug welds you're meant to add an extra one between each 2 spot welds.

[@StevesMachines]

I may look into that and bear it in mind

[@Tasmanian_D3vil]

Leavs coming from fresh air inlet... (to cabin) It's simple af, every old car have this problem...

[@StevesMachines]

All my old cars had sealed sills, I've seen leaves and acorns I'm the scuttles and arches but not sills. Turns out the volvo has inlets in the engine bay designed to push air through the sills to stop them rotting.

[@terryatkinson3182]

Excellent welding with that shite welder, was playing with mine today and if we ever get a decent mig we will be experts 🤗

[@StevesMachines]

I've got all the bits there to convert it to gas fingers crossed it'll be better.

[@terryatkinson3182]

Are sills expensive for the Volvo or is it a spurious part?

[@StevesMachines]

£60 a side plus postage

[@PhazerboyProductions]

Where is Part 2?😁

[@StevesMachines]

It will come soon, it's rained every spare day.

[@pattyseree]

Did you complete the job? Part 2?

[@StevesMachines]

Part 2 coming soon, it's rained here constantly for months

[@colrhodes377]

Always the same, the more you do, the more you have to do.

[@stanislavs9660]

Cool job! Klokkerholm parts?

[@StevesMachines]

Yes Klokkerholm.