Failed inspection about a week ago for loud exhuast (on purpose) thinking they wouldn't look to closely at other thngs. The inspector walked under the car and instantly started to claw and tap the underside of the body. Comes back and tells me I failed for having rust holes on the underbody and I have to get them welded up. I knew there was some rust under there, but didn't think it would be a big problem. It didn't seem that bad at the time when I first looked at it.

Prep work getting started on the rust holes. The rust didn't seem that bad at first until I started to do some grinding. The holes just got bigger and bigger until I found fresh metal.




Ended up cutting out the pinch weld as well. It was so jacked up from me jacking up the car in the wrong places in the past.





After cleaning up the rest of the rust and welding up some new metal and forming a new pinch weld. Sprayed with some primer and then sealed.






Got it inspected and it passed with flying colors. I went there before I added the final black rubber coat so they can see the work I put into it. After I sprayed the final rubber coat everything looks great. Looks like what it did when I first picked up the car 9 years ago.





The fender was also rusted out and was actually just hanging there. So I made new mount and mounted it to the the pinch weld. The old mounting bolts where snapped.

 

Looks real good man. That's cool you did it yourself.
I have some rust on my car that I need to take care of. It's similar to yours, but not that bad yet. I've already been poking and peeling, and took the carpet back.

Did you take your carpet out after taking the seats out, or just fold it over?
I was going to pay someone to repair mine after I stripped it down because I have no welding experience.

 

Took the seat out and folded the carpet over. Also moved the wiring harness to the side so it woudn't get burned.

I had some help with the welding. The first couple of spots I tried I ended up burning a hole. lol.. The welder was turned up a little high

 

Inspections in Germany are no joke! I have a buddy that just moved out there w/ the Army Corp of Engineers, he was looking to get a fixer-upper but after looking into how much work would be involved he decided to save up and get something nicer.

 

The inspections really are no joke over here. Thats why I try to fail something on purpose like leaving a brake bulb out or leaving the cat out so that its loud (95db limit) so they wouldn't go searching for other crap to hard. Sometimes it works, sometimes not. Worked for me last year.

This is the on base military inspections. I couldn't imagine what the T.U.V would be like.

 

wow haha, that's so lame. looks good all cleaned up though

 

I disagree... Inspections should be pretty tough, especially when you have no speed limit on one of your major highways.

Look where OP is from.

 

This is very true and one of the main reasons they are so tough. Definetly don't want something falling of @ 150 mph+

 

don't you need those oem "holes" that were on the rocker/sill panel for drainage? (the round holes which you apparently covered up, they had some rubber plug looking things in them in one of your before pics). I am replacing my entire rocker and rebuilding the entire section myself and was wondering about those holes. I was also told not to seam weld my pinch weld because of drainage issues. my pinch weld looked like yours with more sections missing but I just leaned my new rocker pinch weld up against it and plug welded it for now. I think I am going to stitch weld the pinch with 2 inch stitch welds to make sure its on there good and tight and keep some water from the road out. I think I am doing to much work to a car that I am learning to drift in frankly.lol, its my summer daily as well though. inspection in VT,usa is pretty lax though unlike yours. I did it for piece of mind and structural integrity.