Rusty Passenger Sill

Found some rust.  Two holes, one at the back of the passenger side sill and one on the passenger side floor. The rear sill hole was picked up on the last MoT, and there was an advisory for it as it was ten inches from a suspension mount.

After cleaning up the rust with the wire wheel, I cut out the rust out ready for welding. The two holes can be seen below: 

The back of the sill rust had been poorly repaired before. You can see the spot welds in below.

This other hole is on the other side of the inner sill. You can see the nut for the back of the belt bolt.

Treated the areas around the rust and sprayed as far in the inner sill as I could reach and the gap where the seat belt mounting point lives (the second inner sill) with some Jenolite rust converter.  

This provides a base for the wax oil to sit on top of and should stop any rust from developing and spreading further.

Access to the inner sill is via the plastic grill on the door pillars, and once the front seats are removed, you can access the secondary inner sill.

Below are the areas you can reach via the plastic grill on the door pillar. You can see here that there has been a repair before at the back of the driver-side sill. The large round hole provides access to the secondary inner sill.  

The passenger side inner sill is below. You can see here that a repair was also done, but the section beneath the repair has rusted away. This happened because the rear window seal did not keep out water, as the bottom lip it mounted against was slightly rusted. This has been cleaned up and painted, and the rear windows were re-sealed when the rear speakers were installed. 

 

With the seat removed, you can remove the old soundproofing, which has dried out and was loose. 

The hole below can be used to access the secondary inner sil. The seat belt mounting point is directly behind it. I am unsure why this area has rusted through on the passenger side floor. The rust has started from outside the car, maybe from a previous repair, as the sills typically only have one lifting point per sill. A second set has been welded in at the back of the sills of this car near the rust spot. So maybe the old one collapsed 

The welding looks good, but left a welding smell in the car. Which I aired out by leaving it for a few days with the windows down and the sunroof out.