Bubbling in the side sill

[slitherv10]

I know a few of you must have had this problem as well as it is a common one among Gen 2's.

Anyone have any recommendations on how to fix the problem ? They are aluminum and I am guessing you have to poke out the hole, clean it up and fill it up with aluminum and sand it down. Is this right or?

[Sybil TF]

Bubbling as in paint? Just had my sills repainted. Paint had some bubbling from stock cats getting hot. Dumped those for some hi-flows. Also I had a split up at the front that had to be welded. Wasn't cheap.

[slitherv10]

just finished getting the sills out and scraped away the bubbling and found a small pinhole right through the sill. the other one was fine. Going to take it to an aluminum welder and have it fixed and repaint that area and clear coat the rest of the sill.

[plumcrazy]

body shop.

[ICPREY]

Might want to think about adding vents on the bottom or at least in the front and back before you have them painted.

[slitherv10]

Might want to think about adding vents on the bottom or at least in the front and back before you have them painted.

did think about that but was told, considering I don't have side exhaust and or cats, that it runs warmer now than it did when in had the cats on.

I figured I would just drill some small holes in the front flap that covers the sill opening and that would do the job, but, I started thinking about all the dust and debris that would through those small holes and inside the sills.

[ViperTony]

I installed the side sill vents from Speed Tactics and I believe JonB sell them. I noticed no difference in the amount of debris entering the side sills with these vents installed. No issues. You may want to consider venting the underside of the sills like Dave6666 did back in the day. He has some write ups and pics on the Alley.

[Sybil TF]

Mine would burn you with the stock cat. With the hiflow cats it's warm but wont burn your hand if you hold it there. My front is vented

[ICPREY]

did think about that but was told, considering I don't have side exhaust and or cats, that it runs warmer now than it did when in had the cats on.

I figured I would just drill some small holes in the front flap that covers the sill opening and that would do the job, but, I started thinking about all the dust and debris that would through those small holes and inside the sills.

The exhaust is a lot warmer with cats vs. without or high flows. Here is a picture of my screens on the front and rear of the side sills. A competent body shop should be able to handle it with no issues.
http://i240.photobucket.com/albums/ff228/speedracervr4/VIPER/d02b_3_zps5916ffe4.jpg (http://s240.photobucket.com/user/speedracervr4/media/VIPER/d02b_3_zps5916ffe4.jpg.html)

[gage]

I have screens on mine with stock cats. It will still get hot sitting around but after a nice drive the sills are very cool.

[ICPREY]

There is a guy on the Alley selling a set of premade sill vents..