Allegro Club International

alan wilson · Posted: Sun Sep 19, 2010 4:02 pm Post subject: Rear sill rot

Hi all
I`ve just started attacking Matt Whitely`s VP with the angle grinder, thought this might be of interest to others. Matt took the sill covers off a while ago and uncovered a VERY familiar problem - the rear of the sills were extensively rotted. After cutting out the rot, this is what was left to deal with:

I`ll be taking pics of the repair process as I go along, maybe it will help other members in a similar situation. As you can see, the rust has got to the floorpan, jack point and most importantly the stress bearing reinforcement for the crosstube mountings. The whole area needs to be rebuilt in stages but isn`t as bad to do as you would think. The main issue is availability of panels, ie the outer sills and wheelarches. I`ll keep you all posted on progress
Cheers
Alan
PS - SWK was MUCH worse than this !!
_________________
Well someone had to do it.....

bigmatt1975 · Joined: 04 Jul 2009 Posts: 339 Location: Manchester

When Dr Alan sent me these photos ,I did scream Shocked

, However It is good to know that My Car is in the hands of sombody who knows what He is doing.

I do strees Everbody in who has an Allegro with sill covers ,please remove them once a year and give them a good clean to remove any salt,Mud or slime and prevent this happening to your Cars.

Good work Alan you are a Star Smile

Matt

_________________
Matthew Whiteley
1975 Alegro 1300 Super Harvest Gold,running (Named Hector) Harris Mann's Favorite!!
1978 VP1750 BRG To be restored.
1995 Rover 25 Impression x BRG,Daily (named Brian)

Richie G · Joined: 22 Jul 2007 Posts: 383 Location: Newquay , Cornwall

Oh dear!
I have many an Allegro just like that,well done Alan!
Is this vp the lagoon one that was on ebay?
cheers
Richie Very Happy

_________________
We own 7 allegros !

bigmatt1975 · Joined: 04 Jul 2009 Posts: 339 Location: Manchester

British Racing Green ,The only BRG VP on Earth,thus needs to be saved Smile

Matt

_________________
Matthew Whiteley
1975 Alegro 1300 Super Harvest Gold,running (Named Hector) Harris Mann's Favorite!!
1978 VP1750 BRG To be restored.
1995 Rover 25 Impression x BRG,Daily (named Brian)

Richie G · Joined: 22 Jul 2007 Posts: 383 Location: Newquay , Cornwall

Well done Matt
Keep up the good work Mate!! lol
I bet it will look great once the rust cancer is removed,hope to see it at the shows next year!
cheers
Richie Very Happy

_________________
We own 7 allegros !

Laurence · Joined: 17 Jul 2007 Posts: 1408 Location: Plymouth

Hi,

I had a similar situation with my S3 1300 Allegro.

I was imming & amming whether to remove the outer sill completely when I found that the rear of the outer sill looked like yours back in March.

In the end I'm glad that I removed the outer sill because it was rotten in some 'structural' places which I couldn't see with the sill in-situ.

The top of the sill was missing (rotted away) at the base of the 'A' & 'B' posts.

The sill was also porous behind the front outer wing, which meant that water was entering the footwell.

Anyway, when I removed the outer sill, I realised that the inner sill was so rotten, there wasn't much to weld to, so I've now repaired/reinforced the complete length of floor & inner sill & welded on a new outer sill.

I've also made a new rear jacking point & reinforced the front jacking point.

When the outer sill was off I realised how much strength there wasn't, structurally, so I welded 3 lengths of 1'' (25mm) square tube to the repaired inner sill (bit like a bamboo bundle Idea

).

When I first found all the rot, I wished I hadn't started, but I've now got used to the idea, now that I have nearly finished the FIRST side Laughing

alan wilson · Posted: Tue Nov 23, 2010 6:20 pm Post subject:

Thought it might be time to cheer Matt up a bit.. had a couple of hours on it today and started making repair sections for the passenger (worst) side;
the hole under the seat

first panel made

view from inner sill

next one in place

I did a bit more, still need to do some work on the heelboard but welding will commence shortly. Cheer up Matt. I will finish it for next years shows.
_________________
Well someone had to do it.....

alan wilson · Posted: Tue Feb 01, 2011 7:15 pm Post subject:

Had an hour or two spare today and I thought I might do a bit more...
Fisrt this;

Then this:

Finally this:

All butt welded and ready for a thin skim of filler to get it just right.
Other side next (but that`s harmless compared to this side)

Cheers
Alan
_________________
Well someone had to do it.....

AlexB · Joined: 26 Feb 2009 Posts: 404 Location: Southport

Looks like a crackin' job you've done there, Alan.
_________________

'When you're travelling economy, go first class'

bigmatt1975 · Joined: 04 Jul 2009 Posts: 339 Location: Manchester

Looking Really Nice ,So Glad that Alan is Doing this as You Can See Alan likes doing things Perfect,Great job Alan Smile

_________________
Matthew Whiteley
1975 Alegro 1300 Super Harvest Gold,running (Named Hector) Harris Mann's Favorite!!
1978 VP1750 BRG To be restored.
1995 Rover 25 Impression x BRG,Daily (named Brian)

alan wilson · Posted: Sat Apr 23, 2011 9:45 pm Post subject:

Other side now welded:

Matt`s over next weekend , time to attack the scabby bits and start replacing the doors, then off to the paint shop (it`s metallic, I`m not going there...)
Cheers all
Alan
_________________
Well someone had to do it.....

bigmatt1975 · Joined: 04 Jul 2009 Posts: 339 Location: Manchester

Again, Really great job ,Alan Very Happy

Matt

_________________
Matthew Whiteley
1975 Alegro 1300 Super Harvest Gold,running (Named Hector) Harris Mann's Favorite!!
1978 VP1750 BRG To be restored.
1995 Rover 25 Impression x BRG,Daily (named Brian)