The car had been covered underneath with underseal which was about 5mm thick (not your normal underseal) it took a month of nights to get all the gunge scrapped of the underneath of the car so that it could be sandblasted and any rust got rid of once the better weather came in as the sandblasting had to be done outside. Below you can see the underseal which looks fine and you would not think anything lurks below until it's chipped away.
Once the good weather graced us with it's presence the car was then sandblasted underneath which took about 2 weeks, the whole of the underneath of the car was done from the rear valance up to and including the front valance and also the front and rear arches. I bought a 10 Gallon pot blaster to do this and its a great tool for the job, You will need a proper workshop compressor to run the sandblaster as it consumes a lot of air. Each part of the underneath of the car was then coated with Rustroy as it was sandblasted then coated with a zinc primer as pictured below.
Once that job was completed the next step was to spray the underneath with 2 pack Polar white paint, which after months of seeming to take the car apart I saw progress, which gave much needed inspiration again.
In tandem with the underneath of the car work was also being carried out on the front cross member which had just been brush painted before and the rust was starting to come through, also the rear axle was undergoing serious modifications, which we will go into later.
Below shows the cross member sandblasted and temporally rebuilt, then resprayed and ready for installation
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