Dived into the worst corner on an E9 to fix the rust holes developing there; the front struts. The PO replaced the nose clip and the outer fenders at some point, but never dug down to the last level; the thick steel plate. So I needed to do it now ~25 years later. Luckily the thick steel plate that holds the struts came out looking brown, but structurally fully intact.
It just needs some new steel around it, as the thick steel plate was starting to float in space due to the rust eating away it's mating points:
When trying to remove the thick plate, I saw that the spot welds to the area behind the glovebox & A-pillar were all rusted out, plus also the spotwelds to the arched reinforcement inside the wheel well. As also the vertical reinforcement was not welded to the edge of the thick plate (omission during the previous PO resto?)., it was a quick job to drill just the spotwelds on the tops of the inner fender and pull the thick plate out.
I think it's going to be a lot more rigid once I am finished with the body....
The thick plate cleaned up well with an abrasive flap disc. Originally 3mm thick , I think i can live with shaving 0,5 mm off together with the rust.
It will be Zinc E-plated before being welded back in again.
some rust holes appeared from behind it, which I had spotted earlier when looking behind the glovebox:
Here's a pic showing that the horizontal reinforcement wasn't even welded to the strut tower:
And a first new section being fabbed. A thousand times fitting, removing & hammering.