Body panel corrosion near crossmember tab mounts

[Timkodd]

As I'm reassembling the 90 I'm looking at areas like this and wondering what can be done with it to tidy it up? I've rubbed down the corrosion but wondered if I could cut the bottom 10mm off the panel to create a straight edge? What do the majority of people do with these scabby areas before reassembly?

 

[Station House]

ali plate from behind, fill level, sand and paint

 

[discomania]

I cut them out and welded in some new aluminium.

If that's not your cup of tea then I would make up a plate at the back to spread the load a bit and then neaten it up and paint it. It wouldn't be a bad idea to put a small rubber or nylon separator in between the steel of the rear crossmember and the aluminium of the tub as this is what causes this to rot. Also make sure it's all painted well to stop the metals from being able to react.

 

[Dippypud]

I cut them out and welded in some new aluminium.

If that's not your cup of tea then I would make up a plate at the back to spread the load a bit and then neaten it up and paint it. It wouldn't be a bad idea to put a small rubber or nylon separator in between the steel of the rear crossmember and the aluminium of the tub as this is what causes this to rot. Also make sure it's all painted well to stop the metals from being able to react.

Back in the day when we had our Series 3, we did a body off re-build -

we put cycle inner-tube, cut to size in between the steel and the ali -

as the kids were smallish, we had loads of spares - saved all the punctured and split tubes