I had tacked welded it in place at one or two points then stopped to fret over the door gaps but after that all that was involved was filling in all the plug welds attaching it to the A & B posts, seat pan, front seat cross-memeber and rear mount, vertical face of the new front box section and old rear lower wheelarch flange.
Lastly there were a few seam welds on the front inner face of the A post and the inner half of the B post. These areas can't have been possible to reach with a spot welder even at the factory so I copied the original design. I've still not worked out what order the sill structure was originally made in but more of that later.
The last step was to spot weld the whole bottom lip onto the floorpan edge. This is quite sore on the arms and basically involved resting the spot welder on my knee and pushing up against the floor edge whilst squeezing down from above. Hard work but it looks good now : )
Finally, I rubbed the panel back to bare metal and gave it two coats of a rust encapsulating paint even though it has no rust on it! I wanted to waxoyl it whilst it was accessible but worried the fluid might have dripped down later when I was weld the outer sill bottom flange on so I'll need to inject the stuff instead once the outer panel is on.
solid return lip on original lower front face of rear wheelarch area (its actually the outside face of the chassis leg). no repairs needed before plug welding the inner sill to it (you'll need to rotate it 90 degrees anti clockwise in your mind's eye to view it in correct position)
front to mid view of inner sill. unfortunate hammer marks hade to be made to get new panel to meet front seat crossmemeber before plug welding. top and bottom flanges left unpainted as outer sill needs to be welded onto bare metal.
front end showing step where bottom lip meets box section/floorpan interface. spot welds pull it all together tightly. excess lip above box section needed ground back so it won't foul outer sill bottom flange.
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