This is as far as I go with this project. The owner, who is a paint sprayer, wanted the structure of the car solid. he will be finishing the rest of the Astra himself. I will post up any progress he makes here.
This leaves space in my garage for a new project…
Pretty crusty… I had to cut off the outer arch to repair the inner. The outer was then welded back on.
These areas behind the rear bumper had lots of hidden rust. The owner managed to obtain an outer skin for the N/S …
…But he could not get one for the N/S so a patch panel had to be fabricated. Not too stressful as the finished panel will sit behind the bumper.
The rot was cut out, painted, repaired with new metal and coated to stop further corrosion
A few weeks work ahead on this early ’90s Astra GSi. The Owner has had it for a good few years and wants it back on the road for sentimental reasons. 
As with most modern classics, they hide their corrosion very well. Its only when you dig around underneath that you find problems like this sill
Rust chopped out and new metal welded in. The inner sill was then rust treated and anti corrosion paint was applied.
The new sill was then welded in place….
…and closure panels made and fitted.
On to the other side and more of the same.
Red House Classics 