N/S outrigger

[simon.williams]

I’m tempted just to fill liberally with waxoyl & patch this rather than hack it all off and put a new outrigger in. This was the only rust perforated area.

I don’t doubt the sill has more rust inside it, but one a year is enough!

[johnnydog]

If the rest of the outrigger is solid, then welding a patch or letting a shaped piece of metal in would suffice in my opinion.
However, the remainder needs to be very solid if you intend to fill the cavity with 'waxoyl' (not my personal preference, but that's another topic!) - any future welding in that area will pose a potential fire hazard as Waxoyl burns very well....!

[simon.williams]

Patch welded, not beautiful but should keep for a few years! Seam sealer will cover it up!

[valencia]

I think that the repair you have done is perfectly acceptable, it looks like the corrosion damage was fairly localised.
On the subject of out riggeres if anyone has a similar issue, here's my experience of some years ago.
Driver's footwell out rigger was beyond repair, I made a new one by making a card board model which I then flattened out into a template, it took me a while, but the steel version fitted first time.
Both the nearside ones needed new sill ends only, not too difficult to fabricate, and the off side rear one was oddly enough in perfect condition even down to it's
flange to weld onto the inner sill.
All these repairs were flooded internally with waxoyl/engine oil mixture. They were all done in 1993 and still hold good.

This is the sort of damage I was faced with on the drives footwell.

[simon.williams]

You did well to bring that one back from the brink!