Marty,
When you get going you do some mighty work!!

Since the guard stole most of the rail I got to making a new one, very simple with 1 fold, the trick is welding it on at the corner, I had the welder turned right down so not too blow holes or leave tuning sticks to stab fingers with. I did manage the impossible.... Somehow !!

Passenger side hinge surrounds was nicely rotted so the only way is to remove half the hinge plate carefully to access the area to be repaired. Here's the pics

It was a good shaped panel to replicate


Comparison to the original piece

After that it was time to weld the hinge plate back on..

This side kick panel was still solid except at the top, so when I got to access the panel better I got on with making a new piece. In the meantime the top rail was also being made

Replacing the rear drip rail

Here's the rear top rail reproduced and ready to weld in place

All fixed

Just some light linnishing to flatten welds and a splash of sealer primer to hold back any rust.
Next installment will be front floors, as only the very front of the floors are rotted I'm not replacing the complete pans

Hi Deano
If I can find pics of my mk1 van where the floor, inner sill, outer sill and possibly the hinge support cover was all chopped away for new and made parts . And yes the door needs to be on several times (I used long bolts instead of pins) obviously empty the door out first. The guard doesn't need to fitted unless your really butchering back the steel..

I got to attacking the sills this weekend ,. Well most of Sunday... From the pics I showed previously only 1 sill is bad between the guard and jacking point mainly from the factory stainless brightwork covering the sills . Since the price to import them is out of control, I made a section about 700mm long, however it's only from the flat visible to the weld points at the floor. So the part from the door seal to the outer edge still remains ion the car as mine was still in good order.
Reason why I didn't use mk2 sills is they are very wrong , spose I will save them for a mk2 or sell them on ... If I tried hard I could get them fitted but was quicker to make the part I needed. The reason for 700mm is the usable length of my folder lol. I do have pics of what I did so far

^^ so your outer and inner sill are both chopped, and the tunnel looks pretty religious as well.
I guess there's less issue of stressing the floor or the shell sagging as the rotisserie is fixed on the bulkhead?.
And your brace is to set the width position of the sill, because the floor pan is still being tacked.
 
Funny about 700mm panels, my home made inner sill is the same, for same reason!
Nice repurpose of the door skin too.
 

So back to mk1 coup, the front of the floors was pretty badly rotted away so I repaired the front piece up to the wheel house bulge.



The lower front floors were replaced up to the first rib


Both floors were very similarly rusty and the same template was used for each side !


Welds smoothed out. Must say the floors looks worse on camera, after some wire wheeling they came up smooth and shiny so I hit them with primer sealer

Here it is up against the old sill panel ,


It was a pretty close fit with fold angles etc so I cut a length of new flat metal and got to bending up a new part

Here is the the new piece with a notch for the jacking anchor, doing this was a bit tricky but once worked it out it was easy..
So this is at about where I'm at so far to date , I have cut and folded other parts but will update more soon. I'm hoping to get enough done to spray primer on instead of brushing it on..

^^^thats a money shot of the sills. 
I was confused for a while looking at my pile of rusty bits, and thought a non existent inner sill was missing, but it's just the way the outer sill rolls over and meets the floorpan. It goes over and you weld it to the floorpan flush, and only stands upright towards the rear wheelarch.
Dont worry I know what I mean. :)
Totally different to a Capri sill, which has the 'rail' all way along.
 
Good progress Marty.
You'd be in lockdown now if you lived on the correct side of the border with us Vics..