Repairing a rusted out rear sill cap.

[Nissanman]

Then there was this: -

Not much left of the three panels that make up this section.

Looks pretty sad doesn't it?

The rear of the sill panel will need to be cut back like this.

The front outer skin will need to be cut here.

So now it looks like this.

The surgery has got the panels back to sound metal. Now to rebuild from the inside out.

Sill panel is easy one to do, just a bit of fiddling to get it to mate up to the chassis mount properly.

Looks better already.

Rear cap under construction. Leading edge will be opened out to merge with the sill profile.

That is the main cap done, now for the leading edge.

That completes the cap. The centre sill will be merged and welded to the front and rear caps.

Here is the patch for the LHS wheel arch. Simple plate which is also plug welded to the chassis mount.

There is another small curved section to be added to this plate at the bottom LH corner. It forms the inner wheel arch shape.

[Nissanman]

Last couple of repairs to the LHS sill rear cap area.

Here is the little curved corner piece. it needs a 90deg. flange to finish it off...

....which looks like this. Now for the external skin patch.

This section will give me a decent straight edge to weld the remainder of the sill to.
I have built up the edge of the wheel arch with filler rod so it can be ground to a more accurate profile later.

That completes the fiddly diddly repairs.
Now I need to get some outer skins rolled up and I'll finish of the left and right hand sill repair.

[It's a D-A-T-S-U-N]

Very nice work!