Beetle Boxter, Strip Away The Old

Work started, stripped down and removed some of the patchwork to see what was what, A post and B post on the near side not tied in properly and box section sill is pretty much in the wrong place.
B post is 25 mm too far in both sides so first things first its time to make a set of sills and tie the posts back in and create some strength.

First strip back large amount of filler  

The panel has only been tacked in every three inches or so, not an issue as I want to take the panel out and repair whats under.                                                                                                                                                                                                                                                                                                        

Where the Porsche has been stripped away not has been cleaned up or tied in so this is a must

B post is only hanging on, a pretty bodge repair and no support.

B post is really non existent, the replacement sill is badly out of line so the upper part will be removed, the B post will be tied back into the Boxters metalwork.  

Outer sill made and B post in correct position.The running board now fits to the shape of the side sills.

Inner sill fitted, view from the out side, door now has something to fit against.

Another view from the out side

Inside looking tidy

 Every thing is fully welded, inner sections primed with weld through primer.

The sill does taper from front to back, main reason is where the box section was welded in by the previous crew it picked up on two key points front and back so rather than disturb it the new sill is welded to it, the result is megga strong and gives good side protection.