I am replacing the sills & rockers at the moment on my 100-6. The job so far has been needless to say ,tedious. I dont think the panels have ever been removed so they were quite stubborn & cutting out the sill had to be removed w/ the precision of a scalpel basically.

My question has anybody replaced the sills before?
I bought the kilmartin parts, I noticed that one side is longer than the other. I'm assuming that I box the ends w/ the extra material. Is this correct?

Thanks
Ashley

Ashley,
On my BJ8 the outer sill panel had enough material that I was able to cut and fold at 90 degrees the front of the sill to make flanges 3/4" wide to weld to the inner fenders which matched the origional installation. On the rear there was also enough material to make integral end caps from the panel but I don't remember if it was the inner or outer sill panel. Hope this helps and have a good day!

John

Thanks John, that was my reasoning as well.
Also are the outriggers capped off, w/ a thicker metal,or do they just butt up againt the sill.
My outriggers look great, but hard to tell.

Do you have any pictures of your installation?

Thanks again,
Ashley

Ashley,
My outriggers were not capped off just welded to the sill. I had to make the front passanger side outrigger and make small repairs to the others. I also gusseted all outriggers to the frame as standard for the rear outriggers except I put gussets on both sides of the outriggers. I also welded a 12 gage stiffener plate to the sides of the origional outriggers to allow for possible interior thinning and help beef up the reduced cross section where the exhaust pipes go under the outriggers. This was in response to our local Healey experts advice. I would be glad to send you pictures but I have not had any luck getting pictures on this site due, I am sure, to my lack of computer skills. Have a good day!

John

I would be happy to post them for you, if you can E-mail them to me. erandyforbes @ aol.com (no spaces between name, @ & aol.com)

Thanks guys, Posting the pics would be great.

I was actually planning doing some reinforcement to those areas w/ gussets.
Last night I finally got everything cleaned up w/ the die grinder. I'll make some patch panels today & hopefully get those welded in today & fit & weld the sills in this weekend. I'm taking plenty of pictures of the process.

What rust preventive paint does everybody prefer?
I have Zero-rust & have use Rust ecapsulator by Eastwood w/ good results,
I have never used Por-15 though.

Thanks,
Ashley