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[Bill Robinson]

Gents,  I to am working on my sill and need to decide weather to replace or repair. They appear very soild but I am concerned about the inside were blasting cannot get to.  My thought was to cut openings in them, sand blast, weld primer , and weld the patches back in.  this would eliminate the need to disturb the alignment of the panels.  Any thoughs on this method?

[charley fitch]

I just got finished replacing the right side inner sill on my TR3.  The picture that you showed makes yours look fairly good.  What I can tell you  is that, what was rusted through was bad.  But the portions that were not rusted through were good.  If I had yours  to deal with I would simply replace metal where it is rusted through( it looks like your is only bad on the very front of the sill shown).  And then I would treat the outer part with a paint that is used to bond over a rusty surface.  I tried this stuff and it really works nice.  If you are worried about the inside, I would try to clean it ( tip the body and use a pressure washer and let the crude flow out the opening) out while the front end is open and then treat the inside the same as the outside with some of the rust covering paint. It could be sprayed inside while the end is open.  But I see no reason to open up any holes elsewhere if the sill is not rusted to the point of having holes through it. The sill I replaced was missing all of the top half of the front piece along the footwell and the entire front end. The drivers side was only missing part of the front end as yours appears to be.
Charley Fitch 

[Bill Robinson]

Thanks Charlie,  You seem to be a step ahead of me in your restoration so I have been monitering all your questions.  Good luc and keep me updated on your progress and I will update you on mine!  I think your right on with the sill.  I will open up each end and sand blast and clean what I can get at and por15 the rest!  This should save me the agrivation of re-aligning everything.

[charley fitch]

I really agree with the realigning part.  I worked real hard to try to make sure that I did not take body parts out of alignment.  I did this by building a brace work inside of the body before I took the old sill out of the car.  It seemed to have worked rather well.   I had hoped to have the car on the road last Friday.  But have been delayed by gremlins.  So now it should be by next Friday.
Charley