Been grinding the back inner section out today, it took some getting off with it being new metal!
Been looking at the fiesta sills again, tried bending it to the profile but it still doesn't fit as I'd like it to. The Ka sill has more metal to play with, but there's a lot more work involved getting the right bends especially the top fold.
The rear of the sill doesn't stick out now since this the inner part has been cut out, so I'll re-fabricate this area once the sill is fitting properly.
Not being happy about the way the fiesta sill was fitting I decided to take the original section that I cut out from the 2 to the motor factors and see if there was anything closer.
Really helpful chaps at the motor factors found Mk2 fiesta sill (up to 1989) that's just no way going to fit, they also brought out the Mk3 fiesta sill (1989 up to god knows) which I've already tried.
Then there was one that had a similar profile to the original but with a squarer curve if there is such a thing! they said to take it and see how it goes.
I found fitting was a lot easier, no bending to get that curve, just had to shape the front a little to match the front original part of the sill. Have a look at these pic's and let me know if you think it looks cr@p or not.
Now this sill is the n/s part for the car that it's off so it's back to front, but as you can see it's folded just as the bottom lip at the rear finishes, will the strength in this sill be better that the original?.
When we ripped mine out one side had about 6 loose plates inside and the other side about 2. Previous perpetrators had just pushed the old broken repair plates in and tacked a new one on top and just filled over again! The last repair on mine was done the week before I viewed the car as well (all sorted properly now though).
