Sill reinforcement is cut from 16 gauge sheet. I'm making it in two sections as my brake can only bend sheet this heavy in 24" or so lengths.

Forward section is welded in place. Jack point is visible in this photo; it's in good shape after the debris is cleaned away. Floor is spot-welded to the four "ears" on the jack point.

Rear section is offered up. Pitting is quite evident in this photo. Large circular hole in sill ahead of seat belt attachment point is mysterious legacy of PO and is duplicated in the other corners. Markings on reinforcement indicate where NOT to weld. Silver 'paint' is 3M Weld-Thru coating, which gives some measure of protection against corrosion while allowing an arc to strike. Zinc chromate is another option.

Ready to weld it up. As the female threads for the seat belt attach point have fallen off, I 'm leaving the hole covered over for the time being and will attend to that when I attack the inner rocker later.

That oughta hold. Rosette welds are used because there is not a good place to lap weld-- in particular, the ridge above the sill blocks the nozzle. Front and rear sections are joined with a bead.

Door is remounted to ensure it still fits, opens and closes after all that horsing around. (It does.) After each major operation this drill is repeated.

Continued... p8 p9 p10 p11 p12 p13 p14

back to part 1

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