Re: Rusty rockers at 4 jack points (archive)

Personally, given the low price (a perfect 535is can be had for under $8000)and good availablilty of rust-free cars, I would just sell the car and buy a good one, but to answer your question, I would reseal the areas behind the wheels (the plates behind the front tires are particularly notorious for poor sealing), then remove all of the paint/undercoating from the floor/rocker pannel areas, then probe with an awl. Any suspect areas should be cut away well back from the rust areas, then new metal mig-welded in. Only in this way can you even approximate the original structural strength of the car. I would hate to have a loved one hurt or killed in a collision in a cosmetically repaired car that could have been safely sustained by a car without structural rust. These cars are only sturdy if all the sheetmetal is perfectly intact (since there is no "frame" per se).
Bob

I have read in the archives that 8 of 10 e28s in rustbelt climates have this condition. It is true for me too. I am finally doing some bodywork in this area. So far, I have ground away the flaky paint, undercoating and surface rust revealing an intact structure, but with a 3" perforation into the rocker panel, just wide enough to push a screwdriver blade into it. My plan is to is to repaint with "rust control paint" and then squirt undercoating in the holes. Should I plug them up or should I leave them open for water to drain etc??
Sorry for the mundane question, but winter is approaching again and I need to slow this process down.
TIA,
Jack
1986 528e 180K

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