o/s sill repair

Much like the passenger side sill, the drivers sill was also rotted and had been repaired at some point in the past aswell. The previous repairs were rotted through.

As you can see, once the initial metal had been removed, you can see the patch of metal that had been welded on in the past:



The end of the sills were also rotted:



Started to remove the old rusty previous repair patches:






This was all cut out until there was clean metal all around:





A new panel was welded in place - this was tricky as the top of the sill where the wing bolts to was also rusted. This area had to be repaired and the new sill patch was welded to it.

Getting the panel correct was quite tricky due to the shape and here are a couple of shots of the progress of this. Eventually the top of the sill was recessed in and went under the original top of the sill:





After some fettling, it was eventually welded on and treated with POR-15 and also some resin for extra coating:



The whole area was then smoothed off with some metal-based filler, primed and painted with Stone Guard:



The inner wing area here was pretty bad, revealing several holes into the drivers footwell area that were patched up before the new end of sill was repaired.

The whole end of the sill area was then undersealed along with the rest of the inner wing: