My new plan of attack is to start with the worst bits first, so with that in mind I'm starting with the off side rear wheel arch. Its clearly completely shot! The hole is big enough to put your hand through and the rot extends much further than that.

The rear subframe isn't too bad - a bit of surface rust but nothing that can't be treated. The petrol tank (removed in this picture) isn't leaking but its a bit rusty so i think i'll replace it while its all apart. The subframe needs to be removed so I can repair all the other bits, amazingly all the bolts come out without shearing although some of the heads rounded off so a new bolt set will be fitted.

Removing the subframe reveals that the rot has extended to the heelboard as well so this will need a repair. The nearside is also a bit ropey although the wheel arch isn't as bad.

Much chopping and grinding later and a new wheel arch is fitted, well a new front half anyway as the rear part was ok. The white residue in the photo is left over from the phosphoric acid sprayed onto the area to remove any traces of surface rust from the area prior to painting with some anti rust paint.

The rear door step section was also rusting away nicely. Some garage in the past had 'repaired' this with paper and filler, this would explain why there were pieces of newspaper in the rear valence.

Luckily a repair panel is available here so out with the old and in with the new.

Where the petrol tank neck passes through the floor it was very rusty and part of the panel had completely evaporated. This section is normally hidden buy the tank below and a floor panel riveted over it on the top.

This was a difficult section to repair as there are no repair panels available and it is an awkward shape as the floor goes across then down to meet the bottom of the exterior panel, made worse that the curve of the corner of the car also has to be taken into consideration.

This is now fixed... photos to follow.....

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