This was actually quite hard, mostly because we'd done quite a good job at welding patches to the existing sill. We really wished that we'd known that replacing these was not only the right thing to do, but within our grasp earlier. As well as patching that we'd done we were having to cut out the members that Ross's dad had made and we'd put down into the old sill for added strength. This was really horrible.
At the back of the sill inside the car there's a box section where the floor rises to go under the back seats. The end of this was very very rusty on the inside. After Ross had cut the sill off this is what we opened up...
So as well as fitting the new sill, we now have to make a new floor section, new box section at the back and a new foot for the central door pillar which had also rusted badly. This is Ross starting on the new foot...
Meanwhile Mum, Dad and Jo were outside cleaning up the suspension, wheels and associated bits and making them ready for the new chassis. Here's a pic of all the bolts and bits cleaned up.
Once everything was clean they painted the bits up with POR-15. Once that was all dry they set about fitting the parts to the new chassis.
The hardest part was fitting the central suspension cylinders. Not surprising as they'd been the hardest bit to get off. The threads on the cylinders weren't perfect from the damage caused by the rusting, but we managed to fix them up and with lots of lubricant we got the large nuts back on. I'd bought a new nut to replace one that dad had to cut off, and a special spanner specifically for fitting them - both bought from 2cvcity
As you can see they made great progress over the weekend, while Ross and I felt a bit down having basically destroyed a bunch of good work we'd done so far to get started on the new sills.