1975 Peugeot 304 S Cabriolet with hard and soft tops.

Ray - Do you have any images / pics of what was there before / what is there now or even a mock up of what you need to achieve (mock up could be done in cardboard for now)  

Yep    

Ok - I get the picture - It would be easier to form a stepped flange by fabrication and welding this to the sill terminus rather than cutting / attempting to form the required shape & profile on the sill panel itself (especially in 1.8mm thick steel) - So just a matter of forming a couple of 'L' shaped pieces then welding them to the sill end then dress back prior to fitting - I know its easier said than done - form your pieces first / trim & trial fit them as loose sections prior to tacking on to the sill - then trail fit the full sill - that way you can make any adjustments / alterations to the flanged end prior to removing the sill to fully weld the tacked areas up - Don't hesitate to shout up if you don't think it can be achieved in this manner or if you get stuck further into the process - Good luck 

PS - It might be good idea to consume the contents of the cardboard box prior to starting 

Unbelievable. After all that pratting about I found the part I thought I had accidentally thrown out.

The complete front end of the sill. The black line is where it steps in and fits inside the bottom of the A post.







Would have been easier doing that last night but the plan of attack is decided now. Absolutely chucking it down and getting flooded out of the tent so might have to abandon for today.

Thanks for the info vojo. I was planning on using rivnuts for the bottom mounting mounting and will decide on that when I get to that stage. I have the rubber seal for the decorative outer sill and was hoping to use that but I see your reasoning in using a couple of small tacks to prevent any movement.
The self tappers for the kick board (you mean the thin alloy trim which butts against the door seal?) would not be covered by my kick panel which might not be original so I might have to make one with a deeper outer flange.
Off on my jollies soon so will have pictures posted when I have made some progress.
Thanks for your interest and advice.

Proper adapt and overcome stuff , love it!

Providing the primer that the fabricator applied is adhered well then just a key over / scrub over should suffice 

Back on it but painfully slow as always. I got the step in the sill which I was asking about earlier. I was just about to do it the way Chris advised when I remembered something I had seen on Youtube. I had enough length in the sill to make a mistake and start again if necessary so nothing to lose.
I made a couple of cuts on the edge of the top horizontal section, then bent that down about 70 degrees and than back up again. This had the desired effect of putting a small dip in the panel as it did not return to the original shape. The shallow vertical section received a smack (several smacks) with a brick bolster and a large hammer. As rough as but it worked.



Outer sills then had some gussets made so I could plug weld them to the centre sill. I will eventually do the same to connect the centre sill to the inner sill.





The holes in the gussets are aligned so I can pass a very long cavity wax lance through from end to end.



Centre sill lying in place. I need to mark the position of the outer sill gussets and drill the inner sill for plug welds. Might fit more gussets as no idea how many there should be.



Inner sill bent and cut to suit. The panel cut and bent back for access can either be folded back and welded (hopefully) or removed altogether and a new piece fitted. Whats left of the floor will be getting cut out and replaced.





All 3 panels clamped in place. Bit more to do including painting for corrosion protection before I work out the assembly order.



Those bracing bars are literally a pain. The number of times I have smacked my head off them is unreal. And they are not far enough apart to get my head through the gap so i have to crawl underneath and come up through the hole in the floor.

More emmm, next week maybe.

I found that a protective baseball cap is handy when trying to get under things like this with a full complement of skin. Mine was from Aldi, I think, for about £4.99.

The problem is remembering to put it on.