ajlelectronics
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Have a look at my Scorpio repair thread. I imagine that the construction would be vaguely similar.
I often find that fords from this era have wax on the inside of the sill, which is a real fire risk when welding !
Have a feel though those rust holes inside the sill to see if if feels waxy. If you still want to do it, cut a bigger hole so you can get inside & clean all the wax off !
Hi all of this rust is standard on the bottom of a Focus Mk1 due to water getting trapped behind the gunk on the sill. i would cut out and patch repair and then find at the scrap yard a pair of early Focus black plastic over sill covers (you find these on pre facelift cars) fit these and job done.
but smokes like an Aberdonian hooker.
Not sure what you mean by these covers? I've seen the step covers, is this something that goes underneath the sill?
i'd not worry about covers. i'd just make sure that whatever was put on had a good grip and stopped water ingress. that looks like some sort of thick stone chip that has allowed the water to wick in.
I did exactly the same repair (also on an estate) for a mate and 2 years and with 200k miles on the clock it's still going strong.