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Thanks for the comments guys :)


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Finally got some gas today so as soon as the weather allows I shall be getting the welding finished.


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Finished the inside of the old girl and started attacking the inner arches and sills. I was in for a shock with n/s sill as the plate that was welded in 2 years ago has rotted away and the same side inner arch is pooped. The pics I have taken don't really show how bad it is.
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No progress today as I had no tools to change the grinder wheel ( so not been in the best mood). Sorted now but I thought I would have a poke at a suspicious looking patch on the chassis and found this. Oops
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. Think I better go over the whole chassis when I finish the body welding, but to be fair I think this is an isolated patch. Best get some heavy steel to weld in lol


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Just getting started today. This is the sill repair from 2 years ago.
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Well I cut the rot out and treated the tiny bit that was left. Now have the inner sill in place, still needs some extra welding down the back to beef up the body mount. I think this might have been the easy part as now I need to fabricate the outer sill and try to keep original shape so I will be making more temates and taking my time I think
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oh and here is a pic of the pile if rust from this sill not including the pieces that I cut out lol
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Know what your going through, I've cut the whole bit out, inner and outer. And the box section thats goes on the body mount.
 
What thickness steel are you using for body repairs?

Also, when welding on the body, do you unplug the battery, or alternator?
 
I have the batteries disconnected whilst welding. As for steel gauge, I can't remember what it is but I know that it is similar if not the same as original body steel. I bought a big sheet of it from local body repair supplies.
Here is the outer sill I have fabricated using these tools lol. Ready to weld in place now I think
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Not finished but getting there slowly
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Started to rain now so quickly put welder away but here are a few more pics
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That last pic isn't very good but I was trying to show that I've managed to weld up the body mount to the new sill. I have managed to finish this side now so after seam sealing, a spot of filler and paint I can crack on with the other side. I'm really pleased with my sill fabrication as it should look original when painted:)


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Bit if primer until I decide what finish I want, might stone chip the entire sill for more protection.
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Other side getting started
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A bit more of a job this side. Having to cut good outer sill away to get at rotten inner sill but hopefully I'll be able to do a better job
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Well that's it for today as I've run out of wire. It turns out that the inner sill has gone in front of the piece I've replaced which will be a bit tricky to replace due to the drag arm mount being right behind it.
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