Advice on If repair is worth it

Technical questions and answers about the Mazda Bongo

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SirKrabab
Apprentice Bongonaut
Posts: 2
Joined: Tue May 12, 2026 8:43 pm

Advice on If repair is worth it

Post by SirKrabab » Tue May 12, 2026 10:11 pm

I have a Bongo Aero... I don't recall the year but the point is the sills are quite rusty and there's no welders on the island I live on who are capable of the repair. I have learnt how to weld and can do practice welds but I'm trying to work out if this is even worth fixing or if it's too far gone. that and tips in how to weld it or if there's anything that may be broken (due to typical stuff that wears or fails on this vehicle) that would be good to know :D
here are some pictures.
Apologies if the way I've worded anything is odd just not use to writing forum posts :D

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g8dhe
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Posts: 10971
Joined: Sun Apr 13, 2008 10:06 pm
Location: Worthing, West Sussex.

Re: Advice on If repair is worth it

Post by g8dhe » Wed May 13, 2026 7:50 am

Very difficult to tell from the photo's !! It looks quite extensive not sure if its running into critical load supporting areas as well which you don't want to touch perhaps as a beginner.
Geoff
2001 Aero V6, AFT, full side conversion.
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Laz
Junior Bongonaut
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Joined: Thu Jun 20, 2024 8:51 pm

Re: Advice on If repair is worth it

Post by Laz » Sat May 16, 2026 7:01 am

It looks pretty bad but really it doesn't matter whether you have a tiny rust hole or almost nothing left, the rusty metal needs replacing either way.

From what I can see you're looking at new inner and outer sills, rear arches and the little bit between them.

But, you ought to check everywhere, and I mean everywhere, else before buying any panels. Front cross-member/radiator support, chassis rails, wheel wells, rear quarters etc. Basically anywhere where two panels join, and then the bits in-between..

https://bongospares.co.uk/shop/body-parts-panels

Apart from the rampant rust and the horrendous cooling system (on all but the 2 litre) they'll give you no more trouble than any other 25 year old grey import mini van. All the best.
1995 2wd diesel auto AFT 'Montague' rear conversion.
SirKrabab
Apprentice Bongonaut
Posts: 2
Joined: Tue May 12, 2026 8:43 pm

Re: Advice on If repair is worth it

Post by SirKrabab » Sat May 16, 2026 12:35 pm

Thanks for the help!
I'll look into the rest of the vehicle and see if there's even more. hopefully not! :D

thanks for the spares website as well :D

I'll let you know how I get on if I do at all xD
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