I was working on some cosmetic paint repair around driver side rear wheel well, when I noticed some suspect spots on undercoating. Started picking away and found two bad spots and a couple of minor ones.

One is on the spring stop bumper (?) - It doesn't look like it ever bottomed out, so structurally I am not too concerned. But it needs fixing.

Other is sheet metal adjacent to where antisway bar bushings are. Metal is solid where bushing housing bolts on, but sheet metal has gone.

Think of several ways of repairing:

1. Take it to shop and have them weld/braze in new metal. Strongest, but then the inner face of the metal repair cannot be painted and some of existing inside coating will be damaged by heat. Outside would be cotaed with POR and spray on undercoating.

2. Coat everything with POR15 and while still wet, rivet or sheetmetal screw on thin sheetmetal patches. then overcoat with POR.

3. Instead of using sheetmetal, grind back the existing coating to bare metal a bit further and lay up a fibreglass patch using either POR as the resin (have done that in past) or perhaps a 2-part epoxy resin.

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Graham
85 300D,72 350SL, 98 E320, Outback 2.5