time for some pictures of how I've started repairing this,
first up was to make a new jacking point, annoyingly the gap between the two inner sill sections is 92mm so I couldn't buy an off the shelf piece of box section to fit so as you can see I used 2 x 40x40mm pieces of box and 4 x 3mm pieces of flat bar which were all welded together then ground down to give me a solid piece to use with a jack.
next was to heavily douse the inner sill with phosphoric acid to eat the rust inside, I then needed to get into the cavity and wire brush it this required me making a special tool
I actually made two of different lengths to get the whole way along the sill, I then used a magnet to remove the rust remains and treated with more phosphoric acid.
Once happy I'd dealt with the rust as best I could I bought some cavity wax
dinitrol also sell long nozzles for the job
the dinitrol spray was easy to use but worked a lot better after I stood the can in warm water for awhile
above is the first panel I've made to fill the inner most part of the sill, I mocked it up in card first and then transferred it to 1mm steel.
a quick shot of the welding on a piece I needed to attach to the big piece above, my welding's not pretty but there's decent penetration and once ground down is presentable enough for the job
that shows the piece held in place with magnets, ill weld it in tomorrow once I've picked up some more gas. That's the most difficult piece to do the other two section will be fairly straight forward.
