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making the same repair to the right sill
the right hand sill was even worse than the left
inner and outer panels needed
Once I removed the outer skin of the right sill I saw that both the inner support panel and rocker panel were rusted out. I cut out most of the inner support panel and this infected area of the rocker panel.
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Work begins
There wasn't much left once all the rust was cut out. This is the new inner rocker panel being welded in.
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inner support
I made the inner support panel in two pieces - a top piece and bottom - for ease of construction and installation. I will weld them both in then weld the faces together to give one solid support panel. This provides extra strength to the sill for persons getting in or out of the car.
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inner support and outer skin
Here you can see the inner support panel and the first section of the outer skin welded in. I had to take care to insure that the support panel did not interfere with the outer pieces, which took several trial fittings. Once satisfied, I clamped it securely in place and welded it in, then began welding on the outer panels made from the same 1954 Chrysler rocker panel that I modified for the left sill.
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With the new outer skin pieces welded in and some finesse with the body hammer, it is almost ready for paint. It will still require some filler and sanding to get everything looking as though it were never replaced.
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