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Good project report, enjoying reading this one!
Sparky's method is the only way youre really going to get that sill in any kind of passable shape, short of chopping a big chunk out and welding in a new section.
Once you've got it roughly right, just use a bit of filler and sand it back, will be a close approximation of shape, depending on how long you spend on it. Ripple effect can be duplicated by using a schutz gun to apply rubberised underseal to the area. Lick of paint and youll probably never be able to tell the difference.
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