The sills on our mk1 classic have gone from the inside out in the usual in front of the rear wheels/'drain hold areas. Bubbling began to appear last year and the mot tester said it wouldn't make another year. He was right!
So, plan is to repair with some made up repair sections off eBay - £30 per side and break out the mig welder. Think I can keep the repair upto the first sill swage line and between the rear lip and the seam under the door. What I want to do is expose the rusty inner sills and treat them with a zinc based painting system to stop any future galvanic action from attacking the thin steelwork. Drain holes need to recheck - again! You would have thought Mazda would have made an attempt to protect the inner steelwork.
Long term plan is to take off the road at the first sign of 2012 salt and get the repair done properly along with a complete respray! We like our mk1 so happy to sink a few pounds on it to keep it going for as long as possible
If I get a chance, I'll take some pics as I progress the work