any tips on welding patches on innner sills and outer sills they have massive holes in them

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1977 Clubman

would love to have the answer for that one, Lizzie
has a few small holes in the outer sills

buy new outer sills, them put on professionally or by someone very good with a welder - if there are holes in the inner sills it means that the entire sill will be full of rust and it'll keep coming back unless the outer sill is taken off and all the rust removed from the inside and treated properly - patching it just won't work out in the long run.....

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did I tell you that I won a trophy?

Have to agree with Simon.

Either buy replacement sills or have some sheet folded up.
Caution as the sill is actually curved alond its length. To get this resolved use a tip'd hammer and peen the middle section on the inside of the fold, this will cause the sill to curve in the right direction.

To attach:
First drill out spots on old sill to remove and prime any bare metal with weld through primer
Second drill new sill edges every inch with a 5mm hole, clamp the sill in place and then weld the holes up against the underneath panel. NB don’t weld in a circle on the hole, weld across the holes in sweeps. This saves distortion and improves penetration of weld

hi guys

I've just undertaken the task of replacing the outer sills. have taken left off and the inner looked less than pretty am almost finished with the left hand side inner.

a complete replacement is not as daunting a task as you may think. the outer sills are relatively easy to remove and replace. if you have access to an air-saw and chisel it's like 45mins to hack the old ones off. if you dont' have the air tools it's still not a huge deal, just take a little longer to circumvent the spot-welds.

replacements arent' that expensive either, karcraft in sydney have genuine sills for about $60 / side

Yes bought new outer sills $40 each-not bad. wiill patch up inner sills first I think. Thanks for the advice all

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1977 Clubman

Be careful you don't distort the shell doing this! Make sure the door shuts properly before you weld the outer sill in..
I patched the Clubbie's inner sill first, then removed the outer one & replaced it.
The $40 UK made sills are just as good on an Oz Mini as the $60 UK ones, neither are original for an Oz Mini, LOL. Our sills only have one little vent near the rear, which was usually blocked with crap anyhow.
Whatever, don't do the bodge some Poms do and slap a new sill over the old one- it just gives the rust monster more to eat...

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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.