Where was I, oh yeah thats right, fixing rust!
Where there was surface rust the voids and panels have been treated with some rust converter
Repaired then red oxide coated
Right, time to reconstruct everything!
Inner sills...
The panel is plug welded to the seatbelt reinforcers and jacking point braces.
Then plug welded along the inner seam. The outer seam will be welded when the car is the other way round, it is tacked but I need gravity to help my weld penetrate here!
The reinforcer is sliced in half and joined together then stitched to the bottom of the inner sill.
Outer sill, sliced the top lip off and drilled some plug weld holes, tacked in place, checked door gaps.
Plug weld every inch, this may seem excessive but the original sills are normally spot welded every inch or so.
Tack every inch or so along the top then seam the tacks together (slowly!)
Linish and done!
Close off the rear wheelarch
Close off the front cap and inner wheelarch, I hate making these!
Done........ almost!
I still need to seam the inner sill, then make and fit the jacking points. I'll do that after I have done the other side.
The next job will be to repair a couple of rust spots on this side and the rear door bottom before moving onto the other side.