Cheers guys, and yeah, your Panny is sitting pretty much the same, haha. And I know everything is subject to change on the build but I've got an idea on how it's gonna go at the moment so I'll just keep running with that. Main focus is to get the body/chassis done, then I'll move on to other areas.

Those sills look scary! I replaced both of mine..And A posts. .inner sills .. rear arches !
Did you step the new piece down about 5mm so the lower guard sits level with the Sill ?
Keep up the good work ☺

So started off getting a couple of pieces folded up by my brother to replace the rusty section of the lower sill, silly me thinking that's all I might need to do and rust convert what's inside and seal it



But when I cut that section out, any where that was around the inner sill was in usable



So out came the drill bits.... Just when I thought I'd finish drill spot welds.... And I removed what was left of the outer sill at the rear



Then went on to make a new replacement piece the inner rusted out sill before I cut it out just so I could get all the bends pretty close before I mangle it getting those spot welds off.
Got the old masking tape out




And ta da!! Just like that...... Haha not really, there were a few bends on bends that was a bit time consuming but pretty happy with it.


The piece looks not very straight in the last pick but it's just the marks on the metal. It's pretty flat.

And my pile of rust I've cut out so far.


So thats where I'm up to, have to cut that section out now and patch a hole that's in the floor behind the sill, then I can start re assembling it all then move onto the wheel arch. Happy days.

Cheers
Ben

You've got a big job there, but excellent work so far. Keep at it and keep the pics coming too.