Sill panel at last – Part 1

After a bit of a longer wait than I’d hoped, the sill panel finally arrived last week. 🙂

So, with some good weather to play with, I headed down to get started on rebuilding the sill. I’d forgotten what a mess it was, I’d been waiting for the sill so I had a template before I started the job. Here’s what it looked like to start with:

tr7-nearside-rear-sill-outside-3

tr7-nearside-rear-sill-outside-2

And the new panel, ready for fitting:

tr7-new-rear-sill-panel

So after a bit of deliberation as to how to start, I skipped the planning and just got busy with the angle grinder. 🙂 Several minutes later, all the rusty metal was gone and I got started with the new patches to measure, cut and weld. Unfortunately in the excitement I forgot to take any pics until I’d done a fair bit. Still, I got as far as this:

tr7-nearside-rear-sill-cut-for-repair

A few panels cut and shaped later:

tr7-rear-sill-repair-panel-fabricated

tr7-rear-sill-panel-fabricated-2

tr7-rear-sill-repair-panel-fabricated-3

tr7-rear-sill-repair-panel-fabricated-4

tr7-rear-sill-patches-welded

And the finished result:

tr7-rear-sill-panel-welded-outside

tr7-rear-sill-patches-completed1

And after a bit of filling and priming:

tr7-rear-sill-panel-repairs-completed

That was where I left it on Saturday.

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