I bought a couple of panels for the left hand side and started preparing to fit them. The foot well side will be the first to go on, followed by the lower a-post repair. I'm going to try and keep the sill on as long as possible to keep the alignment.
Cutting out the old foot well side its clear that, as per the right hand side, there have been a myriad of bodged repairs to both the foot well and the sills. In order
to fully remove the foot well side i had to cut away some of the sill and lying beneath it were four layers of sill and inner sill! I'm not surprised there's more than one, as the right hand had a new on old, but four layers is quite excessive and shows a complete lack of brains by the previous repairer! After cutting a few bits, wobbling the welds was the quickest way to remove the sill sections as the weakened rusty metal fell apart.
After taking some careful measurements i also cut away the very rusty lower a-post. I need to keep the sill attached beneath this to keep the correct alignment. The lower a-post repair will go on after the foot well side.
There was some decent metal behind the a-post, so i decided to keep this in place and i cut my new foot well side to suit. I'm not sure if this is an acceptable
method for this area, but it seems to work and its strong enough.I cleaned up the edges of the panel to shiny metal and coated in Weld #2 zinc rich primer. Positioned and clamped, i stitch welded the panel in place. It looks better already.
I have noticed that there were several patched on the front of the foot well, so i
will cut them all out and replace with one large patch. Also the toe board will need some work.
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