New sill fitted...

Ok with the lower wing flange repaired - it's time to fit the new sill. With the help of my fellow 'Black Nail Gang' members Pete and Dick and a promise of a BBQ after - Monday of the Bank Holiday weekend was set.

As usual it was p*ssing down, so I put extra cover over the garage doors and setup the gazebo for cooking under.

I had a couple of goes trying a test fit the sill but with three pairs of hands made it easy. Dick brought his new toy a spot welder - which was great and made easy work the top edge. Using the trolley jack and block on the bottom edge we worked along clamping it into position and then spot welded.

Plug welding the A and B pillars and then the inside areas. Finally welding the rear flange of the sill.

Great job and many thanks guys! With the food cooked under the gazebo (still raining) and a few drinks with the ladies it was time for me to say 'now we know how to do it' the other side should be a doddle!

9hrs

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

Front drivers floor panel...

In preparation of removing the sill I raised the car up on axle stands and ramps to a good working height. Removed some of the carpet and rear bulkhead trim.

The sound insulation pad on the floor panel was cracked around large plug - I started digging around to find under pad was rusty, after cleaning off all the insulation I found a small hole in the corner – looks like were the seam sealer was used now has surface rusted along the joints - well done Triumph!

The inner sill was cover with 37 years contact adhesive from the carpet so with some white spirit I spent about hour and half cleaning it back to white paint.

I cleaned out the seam sealer along the bottom of the inner sill joint which with the rusty floor panel I will treat the Hammerite Kurust before cutting out the section that needs repairing.

I also cut out some new plug plates including one for the spare wheel well.

6hrs

A Good Friday and Saturday...

Finally had a few days in the garage to get on... I had started patching the sills with ok results but felt I was chasing the rust along the sills so decided new would be better.

With a recent pre-show discount offer I bought both sides for £190 delivered. But before tackling these I needed to finish what I had started.

Last week with my two partners in welding crime saying bigger is better – while I was making a the tea they cut a large section of the front flitch section. Then showed me how to used the swagger, bending and tack welded in a complete replacement section - thanks Pete and Dick again!

Leaving me to get on I finished off the welding, I patched the turret and the chassis member - with some extra finishing required on the engine bay side, I'm getting there.

18hrs

And more...

Digging around on the sill - I removed some more rusty spots.

I thinking if I can repair these areas and they looks ok - great. If it looks crap - its time for a new sill.

I intend to paint them white not black as before - it looks nicer but the surface needs to be good.

1hr

Hole lot of work and more...

Working my way along the sill and a repair required to the rear lower sill.

3hrs

Sills repair patches...

While waiting for the new inner to come I've made a start on some of the other areas that need repairing/patching.

The front section of sill which is behind the rear of the front wing has rusted along with a support bracket within the sill void.

I wanted to see if I could make the repair plate of one piece of metal - after making a card template and transferring it to a sheet 22 gauge I cut it out a cutting disc.

With some left over angle from the engine stand frame and a length of 50mm tubing - using the vice I bent the plate into the rough shape.

I now need make a replace bracket and somehow attach it to the remain non rusty part within the sill.

3hrs

Down under pt6...

With the car out of the garage for the second time and both near side wheels up on the ramps, I wire brushed the surface rust off the floorpan, also removing the under seal from the sill.

Cleaned up an area just in front of the trailing arm fixing point which has a split in the metal on the angle – this is going to need repairing.

Also cleaned off the filler from the rear sill/lower panel - not as bad as the other side.

Finished off with a coat of Hammerite Rust Beater.

4 hrs