Repairing the Outer Sills – Part 2

In this session, Bob continues with the restoration of the sills and posts.

I then cut out all the rusty areas and came up with a plan to see if I could make it out of one panel. After making the panel I decided to cut it into two panels so I could make the seams on the front corner to look like they were originally.

A couple of hours worth of more nibbles today. I made the final cuts on the front inner fender piece and the rear inner fender piece and trial fit the inner sill and outer rocker panel. Here I cut the piece and flanged the top so it would fit behind the panel on the tire radius and fit out side of the panel by the bracket.

Moving to the back I make a line for the flange and drew up some radius lines for the back.

Here’s a tip – transfer the flange mark to the outer die so you can easily keep track of the line.

And after that it’s time for some trial fitting of parts.

Luckily the out rocker panels screw holes line up perfectly with the pillar posts so I know i am close on the final fitting. It’s time to step back and take a breather and come up with a game plan for reconstruction the bottom of the door posts.

You can see here what I left to do on the front post.

But that will have to wait for a day or two….I have done enough sheet metal work for a while.