Steve, you are right re the clamps for all welding, but even with the compression from the spot welder, I found I got more consistent penetration when the metal was well clamped.
By the way, we do have a few local fabrication shops, I was lucky to find one that didn't really jack the price just because it was a small job - taxes in the fabrication and extra 16 gauge for the supports was 178$ (Canadian).
I do expect though, since I couldn't find a cheap 240V spot welder, that I will have to plug weld the rocker, sill, floor joint, not too worried about that as I can plug from alternating sides.
Tom, I do not mind bending metal, but the rockers since they are mass produced and relatively cheap may be the way to go in the end. I did a quick dry fit with the ones I removed from my car and they seem to fit the new sill relatively well - if not, I can always modify or start from scratch and dump them on ebay or something..
Cheers,
Kerry