Tried a dry fit of inner and outer, they meet quite well right height equally spaced, centre cill bridges gap, but outer showed a gap where it was impacted quite a bit of work straightening but probably worst bit, using a string line lever bar...

Indeed and am beyond grateful for the help That’s great and hope it helps others in what to look out for , it’s certainly opened my eyes that’s for sure and have a whole new amount of respect for welders in what’s involved Can clearly see the...

This is a great thread to follow along with. People often underestimate rust and just how involved the repairs are. You've been lucky here Gary to find such a helpful lunatic to take this on!

Most of rot was caused by damage to outer cill but they all suffer at ends of cill all the bits behind plastic that catch mud, I suppose the answer might be to treat all these areas, structurally only removing lip of cill so not an issue also...

Plus 1 and indeed very interesting to see how it should be done Will be good for future posts when others are having issues of what’s involved in repairing them Plus of course what areas to keep an eye out for as these discovery’s age

@tyregeezer doing some good work there and informative. Nice to see how these motors are built & repaired @gstuart keep the faith…

Omg mate as I must confess I never thought for a second it was that involved Hope ur doing ok and not having to work in this heat I’m so lucky and feel very blessed it’s in such capable hands and can’t even say how grateful I am. , thk u so...

Hi mate Funny anough I had to look up what a joggler was , lol https://www.machinemart.co.uk/p/edge-setterjoggler-with-hole-punch/ Indeed bet that’s fun trying to do it manually particularly if the metal is quite thick Hope ur good mate

Hi managed to get end of cill lower wheel arch out today, very rusty will make a new piece maybe in two pieces, but can now get to innercill to release and cut out rust so one more cut and it's going back together hopefully Bit more...

No it was a manual plier type thing, tried it once and once realised how crap it was have never used it since.

Will probably buy a crap air one instead

I would do what is easiest/quickest, less cut out the better for the car. How are you joggling the steel sheet? I ask as I bought a joggler (cheap one) and it is bloody rubbish.

Was it a cheap air one, as was looking at one may I ask? Yes less is better enough to cut out rust

Hi mate rear part not so good, three layers too have cut out rot in centre part, first will remove rear tub rot roughly white lines this will allow me to remove inner rotten part of cill again roughly marked, as sandwiched between rear tub and...

Sorry forgot accompanying pictures never like cutting out good material when unnecessary so much of this is good inside and out

What you think have cut out damaged outer cill inner cills are rust free, put camera inside no rust or outside or end, don't really want to cut into good factory metal, so have suggested a joggled joint at white line on outer cill at stiffener...

Not to bad so far inner cills in excellent condition cut off some, back half not so good rot to back of inner last foot and under wheel arch liner quite difficult, without burning paint on wheel arch, centre stiffener pushed in 10mm with...

Bless u my friend and knew nothing would get past u , im so extremly grateful Would u mind replacing the passenger side as well plse so then it takes all the worry away of any rust starting again on the sills Many thks for giving it a clean ...

Hi mate started fiddling today, front tubs out trim etc front of cills good will decide where to join as access is limited but no rust, will cut off old full along top with 20mm overlap and drill spots on bottom, rear wheel arch will need a quite...

Hi mate removed the back part of the passenger cill cover, managed to get cover self tappers out, Hands up was proved wrong, hole at bottom/back of cill, but they couldn't have known as you couldn't see, and I poked the hole, inside the cill...

That’s awesome news mate , alas they said they had pushed a screwdriver through on both sides of the inner sills Terrible when ur told porkies with it just being the drivers side At least it’s handy I’ve got the inner and outer sills if the...

Hi mate mot inspector going to go over your D3 tomorrow, going to check brakes, for corrosion and leaks as per proper mot, but am pretty sure their ok, but could be proven wrong, will see, will also check for welding, myself can have a look over...

Ur a true legend mate in helping me with this , oh yes plse ref those cover mudflaps as that would be awesome Really hope it doesn’t give u too much hassle Always wondered that about the engine and food to get a second opinion on it , know...

Sorry mate first pics passenger side as good as my 09

Appears to be all drivers side removed passenger side trim, cill all good outer and inner, when all along underside with a dolly hammer in fact as good as they get, brakes pipes seem ok so far but once jacked up can see better but to be honest...

Hi mate home safe and sound, your D3 is in good company here in Norfolk and has many new friends, (see pic) very quiet motor noticed straight away Will take next day or so to get to a workable position reshuffle needed, difficult to picture...

So massive thks to @tyregeezer for collecting the D3 today , pictures to follow Massive thks once again mate

I know you're nearly there now, but should you need further help, @tyregeezer pulls D3/4 engines in and out for laughs. The man has no fear....

Thanks mate, but more like a sort of madness

Thanks, yes driving around almost daily seems ok so far fingers crossed, nice thing to drive, not as smooth ride as D3 Lol, Yes mate diagnostic a must, topdon payed for itself, took a lot of working out, changing mind and head scratching but got...