Well no images of it Schutzed as the replacement gun didn't arrive. I will put those images links up later.
This lot cover the O/S sill panel repair and the replacement of the rear heater floor with a deeper squarer version.
This was the corrosion inner sill and r/heater floor.
https://goo.gl/photos/U1jPmS8F7m5hUYN6A
Once the filler had been removed from the outer sill two patches were revealed.
The one on the right was nicely done.
https://goo.gl/photos/XWUcGtmW9G1Jc9sn7
I made the sill cut just below the swage on the side panel as the metal above here was sound and the swage in the panel would help lessen the chances of distortion when welding the new section in. The old floor was removed and areas treated with zinc prior to fabricating new panels.
https://goo.gl/photos/U27Me5TY1YwN7Tht6
I also found this little surprise too.
It would explain the low coolant alarm kicking off as i drove it into the shop for the first inspection and the nasty knock when starting from cold.
https://goo.gl/photos/Je7GsMkwpbw8ersv6
This is the box for the floor.
First set show the pinned box being offered up to check fit against the new sill panel section and to mark and pin the position against the chassis longeron.
https://goo.gl/photos/t2ai61AZnGooGNA76
This shows the components of the floor box and the triangular floor stringer in various stages. The reason for the small addition at the end of the floor is that the folder mouth is not wide enough for this length. After zincing the weld edges it was spotted together.
The opening to the right is to allow the loom to run through the inside of the floor boxing.
The holes across the upright are to allow MIG plug welding to the chassis.
https://goo.gl/photos/4DneUzmeQH7AeBgi6
The box was etched and and painted two coats epoxy 1k as was the chassis. The black marks on the chassis are areas to be cleaned to allow for the MIG plugs.
In the Fertan shots you can see I added two angled flutes to the floor and 5 drainage flutes to the sill flange these fall adjacent to the inner panel upright stringers. This is where the moisture collects that causes the familiar sill rot points.
It would benefit owners to drill 10mm weep holes at these points as there is no drainage in the OE setup.
What is not clear from the images is that the floor has a slight lean when on level ground towards the sill flange flutes.
https://goo.gl/photos/Fu2WSXsDcnyxRxNJ8
Once thoroughly cured the sections where re-pinned into position and welded in.
Then a thin runny coating of zinc paint was flooded into the seems and between the welds.
https://goo.gl/photos/BnS9v6h6SbHNxCLSA
Epoxy was applied to the welded areas and sill section inside and out as well as the previously repaired A pillar inner sill & flitch and then sealed with PU sealant.
The sill will not be loaded as there will be a plastic sill cover over here.
In the last picture of the underside of the new floor you can see the rear stringer in place and two holes these will have cowls screwed over them to pull cabin air into the box to help dry off any remaining moisture when driving. They will be fitted after the first schutz coat has been applied. If the gun ever gets here that is.
https://goo.gl/photos/mrqkxpheHqrYWwhm6
