Still cutting and replacing rusted metal. The drivers door sill had a good bit of rust but it was only about 2” from the the bottom so I just cut and replaced the bottom 2” of the whole thing. I have more fasteners to replace but need a deeper cutting wheel to reach inside of the channels under the floor. I am also wire brushing under each fastener before replacement and coating with rust encapsulator. I also removed the seat floor mount brackets plugged those holes with a dowel rod and wood glue. I will have to use wood filler inside on the floor since these were recessed.
Attachments
IMG_6164.jpeg (36.35 KB, 126 downloads)
Door sill repaired
IMG_6165.jpeg (42.76 KB, 125 downloads)
Fastener replacement

Last edited by Southerntruck; 05/01/2026 1:17 PM.

1949 Chevy Carry All
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1953 Chevy 5-window
"Frame off Restoration"
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Please don't tell my wife how much this thing cost!