If there are more holes or dodgy spots lower down on the sills I'd be putting new ones on.
Make sure you fix the rust BEHIND the sill when you get it off... I'd then paint the whole insides with coldgal paint before welding the new sill on.

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DrMini- 1970 wasaMatic 1360, Mk1S crank, 86.6HP (ATW) =~125 @ crank, 45 Dellorto (38 chokes), RE282 sprint cam, 1.5 rockers, 11.0:1 C/R.

I had a floor made of Castrol R cans once

go to a store and get some cold rolled or galve ya titeasses

You can get something a little thicker than normal body panels. That way you can concentrate your heat on the new metal and refrain from blow Mucho holes.

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Galvo sheet has too much zinc on it, I find zincseal welds much better.
I use 1.5mm zincseal for floor patches. I bought a whole bloody 8' x 4' sheet to do the Moke...

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DrMini- 1970 wasaMatic 1360, Mk1S crank, 86.6HP (ATW) =~125 @ crank, 45 Dellorto (38 chokes), RE282 sprint cam, 1.5 rockers, 11.0:1 C/R.

I bought two - didnt have much to spare either

for patches - with the assumption that it will be worse than it looks and therefore will be redone soon enough and a larger scale - I use any aged steel I can find of a similar guage.

If I have found the extent of the problem - either a new panel or a third I use new sheet.

Old computer cases have great steal in em. Some of the older server cases have awesome paint finishes (powder coat in some cases), which won't rust for some time (if at all).

all of this is taken in..... thanks a lot everyone! so in the morning ill be looking around for either old car doors/panels, old washing machines and computer cases??? lol
either way ill find something to do it all up.....

doc.. wats a coldgal?



is that close???

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Here am I sitting in my tin can far above the Moon
Planet Earth is blue and there's nothing I can do...



“A turbo: exhaust gasses go into the turbocharger and spin it, witchcraft happens and you go faster.” - Jeremy Clarkson

No but its warming anyway

Mustn't be that bad, there's no hard nipples

Nope, they're Hot

Nope, yours is better looking.
Coldgal is zinc paint, White Knight I think- it's about 90% zinc and called that because it's like cold galvanising. Galmet does one too, there are other brands.
Good stuff, I welded my galvanised boat trailer 10 years ago and there's no rust yet where I put coldgal on it. Salt water use and all.

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DrMini- 1970 wasaMatic 1360, Mk1S crank, 86.6HP (ATW) =~125 @ crank, 45 Dellorto (38 chokes), RE282 sprint cam, 1.5 rockers, 11.0:1 C/R.

could i use it to paint the bottom/underside of the mini too or do you use somthing else?

_________________
Here am I sitting in my tin can far above the Moon
Planet Earth is blue and there's nothing I can do...



“A turbo: exhaust gasses go into the turbocharger and spin it, witchcraft happens and you go faster.” - Jeremy Clarkson

I guess you could do underneath but you can't put other paints over it.
Most people use POR15 or `stonechip' type underbody paint.

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DrMini- 1970 wasaMatic 1360, Mk1S crank, 86.6HP (ATW) =~125 @ crank, 45 Dellorto (38 chokes), RE282 sprint cam, 1.5 rockers, 11.0:1 C/R.

where abouts do you find these types of paints? is there a cheaper aussie made version thats easy to buy?

_________________
Here am I sitting in my tin can far above the Moon
Planet Earth is blue and there's nothing I can do...



“A turbo: exhaust gasses go into the turbocharger and spin it, witchcraft happens and you go faster.” - Jeremy Clarkson

I dont believe you, I am still looking... and wont stop till I find at least one.

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Click here for the Turbo Conversion Thread!