TR6 Replacing TR6 Outer Rocker Panels Help

[jimitro]

I'm helping my friend replace his outer rocker panels on his '72 TR6. He has full replacement outside rockers from
the roadster factory. Any tips on getting this done?
We don't want to take apart the door pillars. We're thinking
that we will have to cut around these and do a lot of cutting and welding to get this done.
Any assistance would be appreciated.
Thanks

 

[TR6oldtimer]

I first cut the outer sill off, going around the door posts. Using a spot weld cuter, I drilled out the two spot welds on each post where they attached to the inner sill top, and ground the spot welds under where the post 'lips' sat on top of the outer sill. I also cut out the tab under the front post where it attached to the sill. The old metal was then easily removed.

I did not drill out the spot welds where the sill sits under the front kick plate. I just cut the sill off, ground down the remnants, then welded the replacement sill to the outside of the kick plate.

Be sure to take care to support the front post from sagging, and check all door gaps before welding things up.

Question, how is the quality of the replacement sills? The first ones I got were from TRF and need a whole lot of work to get in shape. They went back. The second set came from Moss and also needed work, but a lot less.

The replacement sills, once dressed up should fit to the car with minimal to no forcing.