Inner sill repair

[Spitz]

I need to repair a small patch on the inner sill.

How does one go about this when the sill is full of foam?

I'm using MIG

[MiniDave]

Why is the sill full of foam?

Seems like you'd have to cut the patch out, then scrape out the foam before you can weld the new sheet metal on, cause it will catch fire when you weld on it....

[Spitz]

As I understand it....they put foam in there at the factory

[94touring]

On some they added foam.

Just pull it out of there best you can. 

[Spitz]

A pic of the area I need to repair....you can see the foam in there

[94touring]

Yeah just pull that crap out.  All it does is hold moisture. 

Regarding floor pans, they don't make longer fronts.  You'd have to buy full length or a rear section to use up to the pan section. 

[MiniDave]

I'd never seen the foam in the sill before, that just doesn't seem like a good idea from the getgo.....

[Spitz]

You're right....can't see what good at all putting foam in there would do.
I see Mania has "long" front floor panels listed.
I can't really go full length, as that would require removing the load bed to get at the sill for welding.

An option I'm considering ( I am a novice welder btw ) is cutting out a section from a donour vehicle including a couple inches of floor in front of the crossmember.  I'm not looking at making this a concours vehicle...but a nice driver.

If I can weld in a patch over that hole in the floor you can see...I'll do that and keep the major part of the floor pan