Ok it's about time I attacked my sills. What I have is some 1.2mm sheet steel and 0.6mm welding wire. What thickness is the 340 shell? Would it be wise to change the thickness of my wire or metal?

There seems to be 2 sizes

My guess
Inner/floorpan - 0.8mm
Mid section - 1.0mm
Outer sill - 0.8mm

Repair sheet - 1mm for all
Custom 1.2mm 3 angled section for lower mid section repair (I have some spare, but its not that accurately angled)
Standard right angle 2"x2"x0.9mm from Hadrians for bottom corner of floor pan (although >90 deg)
Standard right angle 0.5"x0.5"x0.9mm from Hadrians good for bottom lip, seam welded all the way along.

I tend to use 0.8mm wire, but probably mainly because I bought a big reel.

Anyway beware what you will find inside!

few more pics on http://www.volvo300mania.com/forum-uk/v ... 3&start=15