Grrrrrr ....

[iandromiskin]

I'm slowly getting around to getting 4 door green saloon back on the road. There is nothing wrong with, but I have taken some panals off to be sprayed and I have to fit seatbelts. But when I got the car I was shown how perfect it was underneath and how it had all been lovely undersealed, and to the credit to the person I bought it off, it was perfect. But the other day I was just grinding down the bottom of the drivers door where some rust had eaten through (the usual) and I saw a small hole underneath so I had a go at cleaning up around the weld around the outer floor panel and low and behold I found a Minors best friend - Rust.... there is a line of rust along the outer edge of the weld and it now looks like I'll have to weld in a new outer floor sill panel (under the box section at the rear offside passenger door). It could have been a lot worse, but just annoyingly unexpected.

[ian.mcdougall]

probably weld was not cleaned properly and primed before top coating. Is it just surface rust if it is just clean up rusty area kill any remaining rust, prime and top coat.

[iandromiskin]

No, its the holey kind. Definately eaten through the metal beside the weld as I can see into the box section behind (which appears fine thank god, but time will tell when I take off the kickplate )

[chickenjohn]

" But when I got the car I was shown how perfect it was underneath and how it had all been lovely undersealed, and to the credit to the person I bought it off, it was perfect."

That is your problem! Underseal isn't lovely it is horrible stuff (especially if frshly applied by a previous owner!) used to hide rust, as you have found out.

Next step to assess the condtion of your car is to remove all the underseal.