Full Day’s Welding for “The Gas Axe” – 2013 Ford Transit MOT Sill & Inner Sill Repair [Case Study]
Yesterday, we spent a full day welding on a 2013 Ford Transit affectionately known as “The Gas Axe”. The van rolled in after failing its MOT on extensive sill corrosion—a classic Transit problem. What started as a straightforward job to fit two new front outer sills quickly turned into a much bigger project once we uncovered deeper rust damage beneath the surface. In this post, we’ll walk you through our process, the challenges we faced, why professional welding matters, and share practical advice for anyone facing similar MOT failures.
Job Overview: MOT Sill Replacement & Surprises Underneath
When a Transit fails its MOT due to sill corrosion, most owners hope for a quick patch. But at Star Welding Mansfield, we never just “plate over” rot. Here’s what we tackled on “The Gas Axe”:
- 2013 Ford Transit – MOT failure for structural corrosion on both front outer sills
- Removed old sills, cleaned back to solid metal
- Discovered hidden rust in the inner sill after initial prep—needed additional patching and fabrication
- Fabricated and fitted new steel sections, MIG welded for strength and longevity
- All welding completed to MOT standard, with a focus on restoring original strength and safety
The end result? A structurally sound Transit, ready for many more years of use—and a happy owner who knows the job was done right.
Why Do Ford Transit Sills Fail MOTs?
Sills are one of the most common MOT failure points on vans like the Transit. Positioned low down, they face constant attack from road salt, water, and debris. Over time, even small chips in paint can let moisture in, leading to hidden rust that gradually eats away at the metal from the inside out.
- Transits are especially vulnerable due to their long sills and exposed underbodies
- Inner sills often rot out of sight, only discovered during proper prep or when outer panels are removed
- Quick patches or plating over rust may pass a visual check, but rarely last and often hide bigger problems
That’s why our approach is always to cut back to clean, solid metal—even if it means extra work on the day. It’s the only way to guarantee a safe, long-lasting repair.
Our Step-by-Step MOT Sill Repair Process
- Lift & Inspect: The van is securely lifted and the failed area is fully inspected—inside and out.
- Strip Back: Old sills are removed and surrounding paint/sealant is stripped to reveal the true extent of corrosion.
- Cut Out Rot: All soft, flaky, or holed metal is cut away, including any hidden corrosion in the inner sill or adjoining panels.
- Fabricate & Fit: New steel sections are shaped to match the original profile. If the inner sill needs patching, we do this before fitting the outer sill.
- MIG Weld: All new panels are seam-welded for strength, ensuring full penetration and a continuous bond.
- Protect & Finish: Welds are ground smooth, treated for rust prevention, then sealed and painted to match the original finish.
- Final Check: The repair is thoroughly checked to ensure it meets or exceeds MOT standards. Photos are provided for the customer and, if needed, the MOT tester.
The finished result: strong, safe sills ready for many more years on the road.
Why Coded Welders Matter: B6 & 6G MIG/TIG Certification
Not all welding is equal. At Star Welding Mansfield, every welder is B6 and 6G MIG and TIG coded. That means our team has been independently tested and certified to perform complex welds in all positions, on both steel and aluminium.
- B6 coded: Qualified for multi-run butt welds on plate and pipe, crucial for structural repairs
- 6G coded: The highest all-position pipe welding qualification, demonstrating advanced skill
- MIG and TIG processes covered—ensuring we can handle everything from thick chassis rails to thin body panels and alloy jobs
- Work is always done to a professional, tested standard—not just “good enough for MOT”
This is your guarantee that your vehicle is being repaired by true professionals, not just someone with a welder and a grinder.
We Also Offer Aluminium & Non-Vehicle Welding
While most of our work is on cars and vans, we also specialise in aluminium welding—ideal for alloy wheels, bike frames, trailers, and custom fabrications. Our coded welders can tackle both vehicle and non-vehicle jobs, with the same attention to detail and safety.
- Aluminium and stainless steel welding (MIG & TIG)
- Custom brackets, mounts, and repairs for commercial and domestic needs
- Welding for plant, agricultural, and industrial equipment
- One-off projects and batch work welcome
If you’re not sure if we can help—just give us a call. We’ll give you honest advice and a no-obligation quote.
FAQs: MOT Welding, Sill Repairs & More
- How long does a Transit sill repair take?
Most full sill replacements take a full working day, but if extra rot is found, allow more time for proper repairs. - How much does MOT sill welding cost?
It depends on the extent of the damage and if the inner sill needs work. We always quote after inspection or seeing good photos. - Can you weld aluminium?
Yes! Our coded welders are qualified for both steel and aluminium (MIG and TIG) welding. - Do you provide photos for MOT testers?
Absolutely—on request, we can supply before/after photos of the repair for your records or to show the MOT tester. - Can you fix rust that’s failed an MOT?
Yes, as long as there’s enough solid metal left to weld to. We’ll always be honest if a repair isn’t safe or economical.
Tips: Spotting Sill Rust Early & Preparing for MOT
- Check your sills and underbody for bubbling paint, soft spots, or visible holes
- Keep sills and wheel arches clean—mud and salt accelerate corrosion
- If you spot rust, get it checked early—smaller repairs are always cheaper
- Bring your MOT failure sheet and clear photos for an accurate quote
- Ask if your welder is coded—don’t settle for “good enough” repairs
Need MOT Welding or Custom Fabrication? Call Us
Whether you need MOT welding, sill repairs, aluminium work, or a custom fabrication, our team of coded welders is ready to help. We’re based in Mansfield and cover all surrounding areas.
Or contact us online here for a quick, honest quote. No pressure, no nonsense—just proper welding, done right.
