A lot of the rust was hidden out of sight so wouldn't have been apparent to the tester. I did have to hit the chassis leg with a hammer to break the rust, it's pretty thick metal so mot tester can only use a little window breaker type hammer. In saying that it's 5 Years since it was last anywhere near a station so no doubt the rust progressed a bit since then.
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Managed to get a bit more stuff done today. Cut out a lot of the remaining crusty edges, trying to get it to that point where I can start thinking about making up panel templates with cardboard. The door frame/ kickplate bit is a bit of a pain and the bulkhead upper join where the water flows out the scuttle area, there seems to be like a sandwich of metal panels there with what seems like vulcanised rubber sealer betweem them. I need to dig this out so that I can weld any new metak to the upper bulkhead panel that protrudes down from that section.
Anyhoo I took some pics, granted it looks like I've taken more pictures of the ground and my tools than the car, but you can see if you look closely the bits I removed.
The strut tower and the inner wing section that goes along side it was rusting away on it's lower edge, and up into each corner where it meets the strut tower "top hat" edges
Sorry about the slow loading pics I forgot to edit them down to a more "web-friendly" size before uploading them to Amazon s3.
https://andrew-cars.s3.eu-west-2.amazon ... e_rust.jpg
Cut this out and left me with this result:
https://andrew-cars.s3.eu-west-2.amazon ... cutout.jpg
The cross brace bit under the floor I had removed a while ago, so along with this and a bit of floor section I cut out today, I took a pic of that. You can probably see it's seen better days:
https://andrew-cars.s3.eu-west-2.amazon ... cutout.jpg
I tackled the chassis leg N/S as well, this was starting to go on the forward facing section and the left side where the cross brace welds on to, so off it came. There's an old repair on the other side of the leg, which you can see in the pic, it's actually ok that bit (why didn't it rust too ), the edges were a bit shredded where I cut off the lower section, so just trimmed that off after taking this pic:
https://andrew-cars.s3.eu-west-2.amazon ... cutout.jpg
This one, it's more like a picture of the ground underneath where the floor used to be lol, but you can see the edges of the remains of the good bit of the floor.
https://andrew-cars.s3.eu-west-2.amazon ... cutout.jpg
All in all a monumental bit of work to get on with, but it'll be very pleasing to finally start "building back" out the way, new floor pan, new cross brace, chassis leg repair, then I'll have something to work with when putting the repair on the kickpanel side, and also something for the new inner sill to join up to.