Old and New Sill - Passenger side

Old and New Sill - Passenger side

Drivers Side Detail - Inside

Overlaying Sills for Comparison

All Sills - Old and New

Phosphate Coatings

All Pieces Side by Side

Phosphate Coated Sills

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The sills (sheet metal covering the wood below the roadster turtledeck) were really bad - one had a big chunk missing from rust.  Rather than cutting and welding in patches, I decided to get a replacement part from Howell's Sheetmetal in Nederland, TX ( www.fordor.com ).  The part number is S-165 and current cost is $45.00 for the three pieces.

This is the original passenger side sill and a replacement from Howell's.

The drivers side sill - old and new.

Drivers side sill - both old and new showing the inside detail.

Sills overlaying each other - holes line up perfectly.

The old and new sills - a great replacement and all dimensions are identical.

While at Brent's sheet metal clinic, he showed us how to protect shiny sheetmetal from rusting.  Spray it with metal prep and it will etch it and leave a phosphate rain-resistent coating.  You can get the Jacso from Lowe's and the Metal Ready from POR-15.

Shot of all the replacement and originals.

After coating the sills with phosphate..

The sills are a virtual exact match.  All dimensions and holes are correct.

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