Tricky repair started today
From the upper side it didn't look too bad
Under the two layers, however, quite a bit of rust damage to the floor pan part that runs up the inner side of the sill was evident
I needed to remove more of the upper section
Made a bit of repair section from 1mm thick Zincor
Cutting out the rusty bit on the floor pan
Hoovering out the muck in the sill (now or never)
Welded in the repair bit on the floor pan
Upper section going in =>
Trimming the top =>
Most of the job done =>
The inner side of the floor pan welding is really difficult - access is dreadful. I've spot welded it so it is a solid repair but I need to figure out some way of finishing the job.
To make a perfect solution it would have been necessary to cut away the whole sill then repair a massive chunk of the floor pan / inner section of the sill - then refit / replace the outer sill. This would have been a bit of a nightmare so I've gone for the solution shown above. The difficulty in doing it this way is getting access to the join between the floor pan and the U shaped repair section...
...to be continued