Sill replacement

[FrenchStag]

Thank you for all the spotweld removel tips. Better quality tungsten spotweld drill bits from a machine specialist, at a slow speed did the trick.

Now I think I have cut out most of the rot and its hopefully time to start putting new metal in.

I have a few questions still (as I really don't want to do this job again).

For the very inner (carpet side) sill panel I need to recreate a metal strip that sticks out below the floor pans (about 20-30mm). I can either just weld a strip of metal onto the bottom of it, or alternatively spot-weld some larger "plates" onto what is left of the sill, with part of these protruding below it. Any thoughts on this?

Also, I seem to have uncovered a mega-bodge in the front part of the sill, where the footwell side panel seems to have been welded to the middle of the sill, and not at the inner side where I think it should be. Hence I have a big gap to deal with. I am thinking of cutting or releasing the footwell panel at the bottom, then bending it inwards to close the gapo and re-welding. Still a bodge, but hopefully a better bodge!

I have new middle and outer sills, just hoping I can cut them propery and make it all fit together.

Thank you,

Simon

[FrenchStag]

Think I've answered my own question on the bodge. I just cut out everything in the front section that belonged to the old middle and outer sill. It looks at lot cleaner and at last can see how the new material will actually fit. But what a long and horrible job - involves getting up close and personal with the angle grinder and have had some very near misses. Next time I might leave this to a pro...

[jbuckl]

Looks good.

generally cut back to good metal.

sometimes leave corroded to keep a reference… to be replaced later.

[Ian Durrant]

Looks like a competent job to me, you don't need a pro!