Finally ! Passenger Side Outer Sill replacement part 1 of 3Hillman Imp Mark 1 - Project Doris

After a bit of a delay I am back on the outer sills. A lot of fuss tends to surround this with loads of opinions that vary in many ways and none are really incorrect. Some people prefer to remove all 3 parts of the sill section (boxed area, middle sill and outer) then attach back to the car as one, others will do it patch work fashion.

If you want o see a really lovely job rebuilding from parts please visit https://icl.nx12.com/viewtopic.php?t=... where Scott Clements is doing a fantastic job or bringing Amy's Chamois Coupe back to life and covering parts that I might have missed out. Loads of pictures and explanation using all the same panels from Ex-Pressed Steel panels.

Still onto the video, part 1 of 3.

Part 1 here shows the tear down and external panels needed to be cut into to access the sill section, I had a few more discoveries on slight differences to later cars but all are easy to work around.

Removing the sill is quite an easy task, taking car NOT to remove too much material from the lip under the door not so much, remember using a flap disc to remove carnage removed material from the overall thickness which is what we do not want on structural seams. So here I have weakened the spot welds by selectively grinding them till almost through, allowing me to peel off what is left in a ribbon.

This leaves very little to flat off and does not damage the remaining lip to badly