Driver Side Door Sill Repairs

 

This isn't looking too bad...

While there was rust in the castle rail box section, it was only at the very front of the panel.   

So maybe there is a little more rust in here.

 

More rust to cut out then new metal going back in, this is an extension of the floorboard inside the car.

I had to make the the front section of the castle rail. I didn't feel like buying a whole one just to use six inches of it.

Same with the membrane, a small sheet of 16 gauge steel is $10, the whole panel is $87. I added the stiffening triangles with weld beads, probably overkill. 

Membrane primed with weld through primer, new sill trimmed.

Panels installed.

Welds ground down, all good, will finish off with some POR-15 and then put the new splash panel on. The fender was not rusted through on this side making my life much easier. The driver side repair took about three days, but some of that was waiting for 16 gauge steel. The passenger side repair took three weeks!