this isn't accurate to scale but it shows the basic layout
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black, floor pan inc inner sill (one large piece)
green, door step
orange, outer sill
yellow squiggle is the void between them
the orange bit can be vented as you can see in the pics above which lets it breathe and drain out
I painted mine inside with waxoil based underseal which did mean I got a few whiffs of smoke when I plug welded it together, I also plan to waxoil as mentioned above
the outer sills are quite cheap and the work involved is relatively minimal. it is a bit of a rust trap so with pretty much any old mini you'll want to take them off and inspect underneath if there's any amount of rebuilding going on
(apologies for jumping in on OP's thread but it seemed relevant)
Edited by stuart bowes, 17 January 2025 - 12:38 PM.