As you can see from this I've taken the boot panel out. What a darn tedious nightmare it is to remove all of the spot welds! Anyway, as you may be able to see in the picture, the underseal doesn't cover much, especially any of the crevices that water and muck just loves to stick. A lot of the panels around the outside have rusted as well and there are some very nasty rust spots in the wheel arches (big enough to get my arm in). I don't want to take the sills off yet, but I suspect they are in just as good a condition.
After a good clean up and a lot of angle grinder action we are back to bare metal and ready to weld on new bits. I've decided not to paint the chassis or cross members as the rust is only surface, so I've wire bushed off the worst and used a high zinc spray to cover the tops of everything. When I've put the panels back I'll underseal the lot and it should last for quite some time. More pictures to come of the boot panel going back in and the nightmare that is undersealing
