Had a spare day today so got a bit more done.

I've been taling it slow unpicking things bit by bit and working out the best way to get to the bottom layer, then be able put it back together again.

After getting out the rusty stuff, I thought I start with the chassis outrigger. Frustratingly, I didnt have a whole section in my collection so it was cut out bits and refit then weld.

Si far so good, I'll need to dress up the welds a bit. Somehow I didn't get any photos when I'd cut out the thin stuff. The before photos never look as bad!

Might have to get a small air cut off wheel? Found acees with the 5 inch very difficult.

Nice bit of work there. Of the replacement panel isn't a hard shape you could make up what you need.
As for hard to reach cutting spots, I go to my cheap plasma cutter for help, or even the MiG, just turn it up and burn it away !

I'm suprised how much Dave's Garage on YT uses his regular jig saw with a metal blade when cutting replacement patch panels.
No reciprocating saw, nibbler, air shears or anything, just a jigsaw.
Repair is coming along nicely. Hit it with the flap wheel and no one will ever know.

Sharpen up a cold chisel works as well for those hard to reach corners

martymexico
Nice bit of work there. Of the replacement panel isn't a hard shape you could make up what you need.
As for hard to reach cutting spots, I go to my cheap plasma cutter for help, or even the MiG, just turn it up and burn it away !

Hey that's a great idea with the MIG. Don't even need to turn the gas on!

Whats gas?

Have had a fair bit on lately and haven't had chance to get in the shed. Today I managed a short stint in between household jobs.

Managed to drill out yet more spot welds and prepare the last of the small patch pieces.

Didn't get time to zap them in before work however the next time I'm in the shed hopefully I'll start putting some more metal back into the car.

Sill section coming together ok.

Few bits where the cuts were less than ideal, however fortunately these are all lapped sections so will make for an easier fix and still retain plenty if strength. Found it tricky getting the cuts right around the profile. Will be filled and hidden once welded.

Fortunately the sill join sections and footwell butt cuts went well.

Seemed to be lining up 'ok' given lack of consistency from the factory. Ie, between 2 jacking points on differnt cuts have 9mm of variation!!!

Looking good mate

Well, its on and it's solid.

Not the best, not the worst. Few more pinholes to sort out then to move along the sill. In hindsight, I should have just replaced the whole section. Glad I'm not doing a full resto and paint job.

Primer, skim of filler and some paint should blend it in nice enough for what I'm after.

Already I can tell, by the time I get to the end, I'll want to redo what I did at the start. Trying not to be too precious whilst not wrecking a rare car is a battle.

At least this corner is done, I'll leave the guard untll later.