Door step and outer sills

The next job after the inner sills was the door step. This required a lot of care to make sre everything lined up when I fitted the new panel, so the first thing was to take lots of measurements. I made alignment marks both on the car and on the ground and then measured the distance to them from the old metal.



Next I started to cut away the old rear bins and make up repair sections. Quite a lot of metal had to come out!



And then repair sections were let in





With thatdone I could start letting in the new door step and rear quarter. Here it is tacked in place


Thankfully all of my measuring paid off as it all lined up perfectly!

The door step was plug welded and seam welded in place. I butt welded it to the rear quarter panel.





The new door step in place, next job - the outer sill!



The outer sill was very easy after the hard work of the inner sill and door step. It just plug welds to the doorstep and the floors, so I just had to position it correctly and then plug weld it.

In this photo you can see how many plug welds I had to do to the outer sill. (Lots).



Next it's just a case of sanding the welds down and priming it, like this



And job done!