further fiddling : - /

Now that the old inner sill has been removed, the floorpan edge and box sctions have been repaired & the new panel drilled to be plug welded on you'd think we'd be 'good to go'..... well, not quite: The bottom of the inner sill has a horizontal lip which sits on the floorpan edge and is spot welded along its entire length. This interface is however interrupted slightly where the front box section meets the front floorpan and - rather more so - where the rear floor pan meets an intermediate panel just in front of the rear box section. The 'height' of the inner sill had to be reduced slightly at the rear to accomodate this step. At the front it needed to be hammered down slightly.

front box section tucks under front floorpan creating small step.

towards rear of car an 'intermediate panel' between rear floor pan and rear seat vertical face creates a step too. I suspect this panel was brought in when the LWB models were introduced.

rear of inner sill folded over slightly to reduce height at 'step' & along edge of rear box section which is made of thicker metal than original and has slightly higher lip profile too.

trial fitting inner sill at 'intermediate panel' area. row of holes will be plug welded to vertical face of rear seat area.