Just remember to fish oil/epoxy in behind the welds or they'll start rusting real quick again. Good job on the sill chunk, well done 👍

Thanks

I've added a few extra drain holes to the sills near the weldy bits for ease of access and application of fish oil. I treated the backs of the repair sections and sprayed them with zinc. Hopefully that'll hold some of it at bay....

Shaun

Few more patches going in. At least they seem to be getting slightly easier and a bit quicker each time?

Again, not the neatest, was a bit tricky getting the layers right with a combination of but and plug welds. I'll go need to go around and fix the pin holes later, however at least there's mostly metal now where once there wasn't...






And onto the next one.

neat work, especially considering how thin the steel is.
 
You might be lucky having access to original sections for your cuts, but I still dont envy you doing the sills given the repair patches are 50+ years old too, and nearly just as thin. The sills a very visible area too, so double points.
 
Careful, you might get hooked soon and go looking for pieces to chop out and replace, and before you know it, resto done.
 

I can feel some lead wipe coming on

Another patch panel...

It's a bit like welding aluminium foil... 😀

Whilst this one turned out OK, I'm glad the sills have a coat of stone guard which will hide my welding sins.

Currently working on the rear section of the sill where it meets the rear wheel arch., and it has been a challenge.

I didn't have the rear cut curved section so had to modify what I had from a B pillar.

Concentrating on getting the sill section right first as the guard section will come later. It's all paper thin. Been chasing holes for a while. Not sure if I'll have to completely do the end of the sill section, depends on how it progresses. Once it's done though, I'm finished the passenger side sill.

Forgot to get some pics, will do so in the next few days.

Shaun

I can see that patch could've been bigger at the sides by the speed holes there..
A good trick to know is to put strips or tabs behind the main panel by plug welding and weld the new replacement piece onto that , a bit like a drywall repair in a house. Chasing those holes, I turn down the current/wire and pull back the gun so it's about 20-30mm from the panel, this weakens the current a little giving more control filling the holes bit by bit , letting it cool each tack . Glad you're using gas too

MarkA
I can feel some lead wipe coming on

Funny you should say that, as I've been looking into it.
 
I have (or had) a big box of sticks and tinning paste that a mate gave me years ago.
One of those things, ive never used and sat for many many years. I vaguely remember throwing them out though, and try as I might, i cant seem to find them.....  (so I probably did). The old case of never needing something until after you've thrown it out.
 
Looking at the price online, it would appear i threw out several hundred dollars worth!
 
If i cant find them, i'll look at buying (expensive) otherwise will have to go some water proof filler options.
 
Shaun

he's getting good at this.
 
One thing I learnt chasing holes, was dont try to plug it directly. Just aim first to get a tack on whatever edge seems thicker, and build ontop of that, then repeat for the other side. Eventually it will span the gap, and you have something to heat up and consolidate with.
Of course I could be totally wrong too!