even getting the sills to the right curvature is a pain in the butt if your making patch panels. If its the pinch weld at the door which has the multiple steps in it the best thing would be to cut out the section thats bad & take it to a sheet metal fab shop & have them bend you up a new one to match.

I had a replacement sill made that way & I hand fabbed the other one, its a pain getting the curve correct.

Thankx dd i didnt relise that i was all one peice ill buy a complete sill anyway.Its no 21but where the doior meets the sill,just below the kick plates.

Which parts have the rust?
11 Floor Side [inner sill]
15 A-Pillar
17 Dash Side
21 Outer Sill Panel

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Be more specific!
That section is a b.i.t.c.h to fix. Takes a lot of time to get the metal bent perfectly to fit that section.
Not an easy fix at all.

Hi guys the sill isnt actually the part that has rust its above that just below the kick plates where the door meets the body,where the door rubbers meet the body.If u guys no what i mean.

I would buy a set of new sills but then cut out sections of it to replace the rusty bits. It will always rust in front of the rear wheels and behind the front wheels.
I would replace about 30 cms at each end with the cut off sill sections.
I fabricated replacement sections but I'm going to redo it with cut down sills next time. This is where I repaired it the first time-

Fixing sill panel rust

It won't be how long it's taking the guy to fix it. Presumably he's just doing a bit here and a bit there between other jobs.
You can't rush perfection!

If He has been in it for 40 yrs I would say he is retired? A month of working on it everyday? But if I were you I would be replacing the sill... It's not a massive job and it gives u peace of mind that the rust will not return... ;) u can paint behind the panel As well :)

Hi guys just wondering is it better to put new sills in my ute,there is a minor bit off rust in the drivers side.Its only about two inches long and doesnt look to be anything major,should i change the sills or just repair it.The guy that is painting the old girl is stripping her back to bare metal fixing what ever is under the paint then repainting her.John the guy that is doing this for me has 40yrs experience and has done a good job before for me,said i will take him up to a month,is that standard.