Anyway the area around the jack points on my 190D is in pretty terrible shape so I started with the passenger side. What I'd thought were streamers of metal hanging out were in fact the rubber undercoating, there was basically no metal there. I cut back to good metal and welded in a bunch of 22ga sheet metal. 22ga seems about like what I was cutting away, maybe slightly heavy but this is an area that'll have a hard life...
I had to weld 2 plates into the side, one big one to cover the old jack point (I hate those jack point jacks, I use a scissors jack and lift from underneith anyway) and a small one up under the door. Then another big plate underneith the car. I slapped some black Rustoleum on and when it had dried sprayed some rubber undercoating on for good measure.
Not too bad I don't think.
This is the driver's side. I spent a few minutes last night picking the rust and undercoating off. Its pretty much the same as the passenger's side, actually this side isn't as bad...Well, back at it...
-Curt
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