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You're doing a great job. I find it really hard if I start thinking about everything I need doing. It's much easier one small job at a time. This is how I've done my sills (well one for now) It's 100x100x4mm I cut in on 2 sides then turned it over and welded it back in. The bit under the...

I do all the time.

If the ends are rusty replace that part like you would any other part. You might have to buy or make new sill body mounts but that's no biggy compared to the work you are doing anyway. Once you've cut the sill off, cut away any floor that is no good. Replace that part of the floor and put...

This is the welder I bought to do mine. TBH, I can't fault it, it's bloody good. I'm using gasless wire and it going ok. It's good for welding up to about 5mm but it's the low setting I bought it for. 35amp on low. Some welders are 50 or 60 amp lowest setting, not as easy to weld thin panels.

It is true that once its done its done, its yours and you know its right. If the sills need doing, do a search for box section sills, much stronger. Have a look at mine if you want, you're not alone. Its a lot of work and you will have to want to do it. Mobile Photobucket

I'm in the middle of rust removal now, I've just done the boot floor. It's all 3mm now with the original panel bolted back in, I just cut the rusty edges off. I'll replace it with more 3mm when I've got some spare cash. There are around 18 M8 bolts holding it down with the nuts welded under...