The objective is to slow, or at best, stop any further rust from occurring. The car body remains structural. The foam was not intended to gain any strength.

Also, there are vent holes already incorporated in the rocker. I DO NOT INTEND TO DRIVE THIS CAR IN RAIN OR ON WET ROADS as mentioned. So I don't anticipate severe moisture. The exposed metal was coated with zinc chromate and while it is intended for aluminum, I have applied it to steel and have never seen rust coming from that steel in a salt water environment.

I have been driving this car since last November and do not feel that as a result of the rust that the structural integrity is, or has been breached. The alternative is to park it and sell parts from it, I don't think it's quite ready for that yet! ........BB

Look at attached pictures post #175 - #190.

Who has the most rust and still drives

__________________
ASE Master Mechanic
asemastermechanic@juno.com

Prototype R&D/testing:
Thermal & Aerodynamic System Engineering (TASE) Senior vehicle instrumentation technician.
Noise Vibration and Harshness (NVH).
Dynamometer.
Heat exchanger durability.
HV-A/C Climate Control.
Vehicle build.
Fleet Durability
Technical Quality Auditor.
Automotive Technical Writer

1985 300SD
1983 300D
1984 190D
2003 Volvo V70
2002 Honda Civic

https://www.boldegoist.com/

Unless you had a written, binding agreement regarding the specific issue's you mentioned, it'd be not wise to express expensive unhappiness through an atty's letter. "I said" / "He said" is of no real worth. We all buy these things as is. I bought my 69 220d knowing that the guy was lying if he was speaking. I factored that in and told him what I'd give him for it. He said, "Yes", I'd already dispensed with his lie's and am dealing with the car's problems one by one. And have had a lot of satisfaction is learning the in's and out's of this car and solving problems and doing the work myself. I think in the long term you would not be happy with yourself if you did some global smear of the guy's name on this site. Just use PM's when you see people dealing with him and tell them to beware. My best wishes. To me, I guess everybody on this forum has one commonality: We all like to turn junk into something pretty and useful and fun.