After a bit of a pause we are back underway with the Series 1 Rallye. The next job on the list is sorting out the near side sill. It was a known problem when I picked up the shell. Unfortunately, it hasn’t’ improved with time.
It had been repaired previously, but not to a restoration standard:
So time to start chopping out the rot and to start adding in some fresh steel. Rear wheel end first…
The rot was just over plated and continued to rust inside the sill.
Full length bottom section off…
Centre section of the inner outer sill doesn’t look too bad.
Bit ropey towards the rear wheel
Rear jacking point rotted through!
That section of panel out…
Horrors hiding behind!
Chopping that crap out reveals the mess – a lot of weight in this sandwich of steel and filler.
Rallye Project 
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