Chaps, for info really, input would be appreciated........
Firstly a couple of pics of the car from the top side for those that have not seen it before.............
Oct 1999, 114k, drives great, engines strong, a modern classic in every way...........
As can be seen this is not a car that is ready to be given up on just because of rust, I will endeavour to correct this.......
Took the rear wheels off today for cleaning, long overdue, not had the car up on stands since last year. I noticed a bit of rust around the jack pad, mainly the paint hole where the rust had removed the paint. This is on the UK drivers side rear.
I had checked these last year after Cemessi's thread and eventual strip out of his M5, had noticed bubbling but nothing that had blown through. There has been quite a progression over the last 6 months. I removed the jack pad and began to pick at the paint.
There was quite a build up so just kept going until I reached a point at where the rust seemed to have stopped and the paint & metal were intact free from corrosion.
I removed the sill cover and found the rest of the sill looked ok (that is until it reaches the front jack pad)...........quite happy about the fact it is contained to this rear section around the jack pad and the sill is in good condition.
I picked out most of the heavy stuff I knew it wasn't good that I was removing bits of rusted metal about 0.5mm thick.......
Then got the dremel out and started to remove the grained in rust.....
Towards the rear end of the sill the metal was shot, nothing left, poked about a bit and created this mess......
In these next pictures if you look through the holes you can see the insides of the panels, looks like the rust has not crept too far away from the jack pad area.
Last year I had the standard rust removed from the petrol cap area, rear panel above the bumper and quarter panel again just above the side of the bumper, after which I coated the inside of both the rear arches with a heavy axle grease to keep the moisture away, been like this for about a year, looks OK....
Time ran out so had to stop, I am thinking of cutting out this entire lower sill section.......
I can measure up and see how the jack pad area anchors to the car. I could then fabricate a new piece and weld in it. Agreed a lot of work but can't see any other options, can't leave it, the car more than deserves the effort....
FYI, The opposite side seems fine, I poked at the paint and it solid, no sign of flaking or bubbling, however the same can not be said for the front, looks a mess there as well, next on the list..............
any input is greatly appreciated................
Thanks
Mike
9Likes
I must admit this isn't something that I've accounted for when I get mine sorted and I don't really have a clue about bodywork and corrosion, I'm not a body shop expert. I remember the dilemma that Scott faced and it's a hard one. I'd get it sorted mate if I were you, your car is great in every other truly worth it 
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