Well as I thought- today dawned nice and sunny after a bit of rain overnight. But rain was due. But so sunny it was I just had to go for a bike ride rather than work on the car. Halfway up Takaka hill it turned really bloody foul and I got soaked. Should have just worked on the car...
So I got an afternoons worth of work in. I welded up the top of the sill then ground it down flat. This is the most tedious bit to do. Grinding. It took almost two thirds of an entire pitch black album to get everything down neat enough to leave.
Next up was rebuilding the bottom of the A pillar but before finally welding it in place I fixed this little hole so any flakes/splatter etc would drop down the A pillar and I could clean it out.
I used the Dremel. I got into using these on the rx3 and they are invaluable for small repairs. I use little reinforced 40mm cutoff wheels that actually last quite well given what they do. Cheaper to buy them on line from ebay rather than at M10 etc.
I use a piece of cardboard, rub it over the edges of the hole, cut out impression, trace onto steel and quick easy fill in patch for odd shaped holes.
I also drilled a drain/access hole before final welding allowing clean up of burrs and swarf.
Once the sill end/A pillar bottom was welded up I painted it with epoxy mastic. This area will get all sorts of *Bleep* thrown at it so will get penetrating wax sprayed in there too.
I made a new wing bottom to replace the dodgy original. I wont weld it in till tomorrow once epoxy is dry.
Finally tonight I cut open the very rear section of sill where there was rust holes through the outer and it was pretty good in there. Evidence of wax or something sprayed in from above near where the rear seat sides would be. But for some small holes on the inner sill end its all solid good thick steel. Much relief. I treated it and will paint it tomorrow before making a new lid.
I'll repair those holes from the other side later on when the car is up on the hoist.
By then It was only about 4 degrees in the shed, the wood burner was going in the housetruck so the decision was easy. Back at this tomorrow. I will not be enticed out on the bike again..for a while..