1983 Rover SD1 2400 SD Turbo Diesel

The next big chunk to attack was the rear end of the sill. I forgot to take a photo before i chopped it, but basically the rear lip was gone, and the part of the rear wing/inner arch that sits ontop had also rotted through. I cut it all away and then started putting it back together again.

I made a few small repairs to the inner sill. I was very happy to see that the captive nuts for the trailing arms were perfect. They can be a curse word to replace as there are two or three panels together. Save me a few hours.

All the rot cut away and cleaned back



Bits welded in



Bonda Primer



Next i started prepping the donor sill. I cut it to shape and then started making little tabs so i could get a feck load of heat in there and not blow holes.









Then welded it in

Very nice - I like the idea of the added tab/lip to prevent the welding wire "hedgehog" (great name for them too!).