I repaired mine with 2mm .
I've actually been through your thread - nice work. It came together nicely tonight - bit of test fitting, bit of cutting, bit of thinking. Think I have the right position for the arch and repair plate. Have to do things a bit backwards as there's no point welding to bits that will need chopping. I've no lip for the inner arch to meet outer that doubles up as seal holder. I think I'll weld a home made lip to the repair panel.
20180628_181802.jpg
20180628_181812.jpg
20180628_210057.jpg
 
May be a bit backwards but had to fit outer arch to rebuild inner. Spent fair few hours on it today. All set and welded in and the door alignment etc seems bang on :)

Got a section of c pillar to add and a tie in from it to the arch for the seal.

Body mount is absolutely wrecked :D

Chopped out the section of 4mm box lol. I have a feeling the bolt won't undo easily.

20180630_162621.jpg
20180630_162633.jpg
20180630_190841.jpg
20180630_191018.jpg
20180630_192153.jpg
 
20180701_142514.jpg
20180701_162719.jpg
20180701_162730.jpg

I've got a gap....

I'm going to weld a 2mm plate onto the repair plate to fix the gap rather than butchering the sill I think
 
Resto ..... yer wheel arch plate with the seat belt nut in ...... the seat belt nut bit looks further in than mine......

Is it on the plate the right way up ??

Optical illusion.....?

Mine from underneath


DD60162E-E3C3-432D-9BB0-DE367B1413C5.jpeg
 
Not too sure but it won't be used anyway I don't think. I want to sound deaden the lot then either ply or carpet. Then it will be set up for me and the dog I think :)

How are you getting on with yours? Where abouts in the world are you? Would be good to compare notes and grab some tips!
 
My little boot floor pot of cash is now going on a fcuking dishwasher. Spent last 30 mins with my arm in waste water. Seeems pump is tripping rcd
 

Similar threads