Decided to bite the bullet and replace the Sills (rockers) on the XJ
Already had some box section 2"x 4" X 3/16"
cut the sill 1/2" below the top sills line
]
and i cut in front on the pinch seam
With the old seal removed you can see what the inner sill looks like.
It has a flat top which is appoximatly 2" higher than the first cut
Using some 2"x 1" boxsetion i was able to fill the gaps around the main box section
so it fits snuggly in the sill spreading the load.
The rear section of my sill was rotten so i welded a section of the smaller box flat against the sill
this also gave me something meaty to weld to .
The orginal sill is not straight and to compensate the back spacer is cut angled starting at
1"3/8 at the front reaching 1"5/8mm at the rear giving a straight line on the outside
I welded to spacers to the box (rocker) painted the inner sill before fitting
the rocker avoiding the areas to be welded. I folded the pinch seam flat to the bottom of the rocker and track welded then tracked the top to the door seal
them seam welded all areas. All welded joins sealed and panited.
