Inner Sill...

I often see "Sill" written as "Seal" and im not sure which is correct, but i prefer "Sill" so thats what i use!

I left the inner sill clamped in position over night. The next day i went out to the garage and found it had fallen off and cut straight through my power cable, which by the way, runs some 60 meters from my first floor maisonet around to my garage en bloc! Fortunately it didnt happen whilst i was working, and i have an RCD on the socket end!

Anyway, with the inner sill clamped in place for several trial fits i was trying my best to get it straight and level. Without the doors on, and no hope of refitting them as the a-post had also gone, i could not check the door gaps were correct before welding. I had to rely on the bracing that was put in place before the cutting began.

Using my Joggler/Hole Punch i made a series of holes along the bottom edge of the sill and around the end flanges of the crossmember and along where the sill meets the footwell side. With the inner sill in the best position i could get it, and level, i plug welded all the holes alternatly so as to not distort the panel.

The inner sill instantly gave the shell a little more strength, but no where near enough. I resisted the temptation to stand in the car and test my work!

Its really starting to look like its coming back together again, the drivers side at least. All this has to bee repeated on the passengers side, which will no doubt turn out much better being that i will have already done it once!