Since I scrapped the sills so far, not including some practice I’m burning through the sheet metal pretty fast. I was looking at all the materials to see if some can be reused and they can to a limited extent. The aft pilot’s door sill that I had finished I turned into the aft cargo door vertical sill. It took a little noodling out, some cutting, welding, but I was able to at least salvage some of the material. I’m really not liking door sills at all. They are a PITA! And the main reason they are a PITA is trying to figure out what they connect to and what you will see or not see. When you’re building an airplane for the first time, it goes so much slower trying to figure all this out.
