If you a have a Mini that is special, locate a damn good welder that will
ensure that the job is done right! for about ?200.
If you just want an MOT to get you mobile and you arent too concerned if the
welding will last for the next MOT, take it to your local garage that will
charge about ?100 for the pleasure.

A good welder will attempt to remove as much of the old sill as possible and
not only replace the sill but also put in a bit of new metal so the job will
last several years.

The garage will fit an over sill, covering the old sill you have already,
with this technique the new sill will sooner or later rust thru.

Jono

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It is relatively easy as long as it is just the sills that need replacing.

You will need a MIG welder an angle grinder with cutting discs and grinding
discs.

Cut the old sills off with an angle grinder. Remove any of the metal that is
left after cutting by grinding off the spot welds or seam welds. You are
aiming to get a single thickness of metal on the joins after the sill is
removed.

Tidy up any rust etc now visible give it a coat of zinc primer. To try and
stop rust reappearing.

Clamp the sill tightly in place

Weld the sill on as the originals were spot welded 1" tack welding or plug
welding will be allowed by the MOT man.

Give it a coat of stone chip.

You should be able to do it in a weekend.

I have some pics of mini with sill off at www.wannop.co.uk

Cheers