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When you take off the outer sills, you will uncover more rust. Take your angle grinder with cut off wheel and cut out the rust. I like the paddle switch grinder as it is far safer because of the switching mechanism. Hopefully you won't find too much rust in the inner sills but they are easy to patch. Don't overlap. Butt to Butt weld only as the lapping will rust worse.
Look closely at where the rear subframe mounting nuts are and in that area where the bulkhead is. Change out to stainless bolts and nuts.
Get yourself a hole punch and put holes spaced 1 inch apart along the lip to weld to the body. Grind smooth. Don't forget the jacking point brackets. Waxoyl if you can do it, when finished.
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IF IT WEREN'T FOR PHYSICS AND LAW ENFORCEMENT, I'D BE UNSTOPPABLE
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6464 , I was never around minis so i dont know much about these cars except what ive read and done myself.I had a 998,a 1275,a disaster of clutch issues and then did the Vtec swap and flip standard length steel front.I have 0 experience on any panel replacement but the rear valance seems like a good place to start on.Are the sills really involved? They dont seem all too bad,but idk if i will uncover some hidden issues.The sills arent all that bad but i want fresh ones.Valance has a small spot about a dime size.
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Better than Heritage.
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I used the aftermarket front end parts (Wings,hood,and nose panel) on my car for the flip front and all seems well.Parts fit decent after a little massaging.