Just thought I'd share my recent findings and the work it caused. 2010 MY SDV6 with 135k miles.

I've spent a bit cash catching up on the maintenance of this car and getting it right. So when I dropped the spare wheel to inflate it, I was a bit terrified by the sight. Thankfully it's mainly surface rust, especially on any areas that are powder coated. The paint on the spare space-saver alloy practically came off in one big sheet! I set to work with the scraper and wire brush, then painted with a rust converting paint and then a waxoyl/underseal mix. New winch fitted too as it seized open.







I knew there would be issues elsewhere as I had already had to replaced the fuel tank cradle which was rotten through, and I can see a bit of bubbling behind the plastic covers on the rear inner arches to the sill. So, when feeling brave one dry day I removed the plastics. The car has had side steps fitted at some point (probably rotted away) but not mud flaps. Seems to me this is the worst combination as the there are no mud flaps to stop spray up the sides, and the side steps plus the cut plastic sill covers just trap all the salty water. Is this rust in the pictures similar or better/worse to what any of you have seen?

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Sorry, not sure why a bunch of the photos show upside down

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Ouch😬😬😬 this was the only patch of rust I found on my sills when I replaced the side steps.



Underside and chassis is much the same as yours. Steve

2005 2.7 TDV6 HSE, ongoing project.
1998 Volvo V70 R auto FWD, mothballed future project.
1999 BMW Z3 (owned from new) garage queen.

That’s nice work. Seem to have caught it in the nick of time. I had similar issues with the sills when I replaced my rotten side steps. However the wire brush was making holes. Out came the welder and all ok now but periodic removal and inspections behind exterior trims is important.

Sorry to dig this one up but I thought I'd check my 2010 rrs and I have to say both sides, under the arch and sill trim, was a bit of surface rust.

Wire wheeled them down, rust converter brushed on, the zinc primer, top coat and dinitrol clear wax on the inside of the sill and the outside and arch. The trim covers the work nicely.

The photos show how much mud the rear arch trims can hold and the amount of rust.
 2010 RRS 3.6 TDV8 HSE Galway Green

Missed one

 2010 RRS 3.6 TDV8 HSE Galway Green