Rear wing front lower repair...

The flange on the rear wing front lower section that's above the sill has rusted with a small hole in the front edge.

I didn't feel it needed a complete repair panel, just a new return flange replaced. After some discussions on the best way to do this - removing the edge and flange back to good metal would be the best option.

I started by cutting off the flange and 3-4mm of the face edge. Then making a repair panel/patch with flaps each end add strength when welded.

Using clamps I tack welded each end and inside to hold in position - then stitched weld along the edge. After some cleaning up with a flap disc it looks pretty good.

My plan with these joints and other areas is to try "lead loading" than filler.

3hrs

Other surface rust...

While watching paint dry literally! I started on some of the other surface rust around the rear screen and top deck, the corner of the boot lid opening and rear lamp assembly.

Cleaning off any rust with wire bush in the drill and then digging out any old seam sealer. Then I treated it with my good friend Mr Kurust.

1.5 hrs

Inner sill...

The inner sill only has some light surface rust on it - after treating it with a coat of Hammerite Rust Beater, I then gave it a couple of thick coats of black Hammerite paint.

I also gave the inside area of the new sill a couple good coats of the black Hammerite.

Just need to clean all the flanges of paint for the spot and plug welding.

3hrs

Floor panel repaired...

When removing carpeting and sound proofing I found a couple of some rust holes in the drivers floor panel.

Using a card template I cut out the patch and folded and hammered into shape. After treating the area with Kurust and seam sealer I welded it in place and finished off with a coat primer to seal until I paint white later when the new sill is fitted.

3hrs

Off with the sill...

With another long weekend it was time to remove the off side sill. A new heritage sill waiting to go on - I started by cutting the bulk of the outer skin off.

Looking at it the other rusty areas along from where I had patched proved it was a good decision to replace them.

I then cut and drilled out the spot welds on the top and bottom joints and from around the A and B posts, then cutting welds from the inside to release and slipped out the remaining sections.

I had a quick dry fit of the new sill with looks like a nice fit. Next I will clean up and Hamerite the outside of the inner sill which has only a small amount of surface rust, I will also paint the inside of the new sill for extra protection.

8hrs