I managed to get my old sill stripped ( caustic soda bath then set light to it with methhanol and kerosene then plunged it into cold water and paint gone!) and then it, my new one and two Discovery tow bracket arms I made for myself down to the galvanisers. Got them back and etch primed the lot, so thats the sills in, seatbox in and floors laid in to check all the bolt holes etc...
I saw Aldi were doing 3m of self adhesive 3M foam tape for about £2.50 (like that used for the seals between the gearbox tunnel and floor pans etc.) so I bought 3 packs of that which will save me about £30. MRC8626 (tunnel to bulkhead seal) is £3.95 alone.
There always was, and still is a bit of a gap between the sill and the floor pan on the N/S, the seatbox obviously has the battery box there, so it seems the extra depth of the battery box metal etc causes the seatbox lip to sit higher at the back, so the floor then sits a bit proud here. Is that normal?