8 hours ago, Ian Lanc said:

You wouldn't believe what I've been doing to keep the rust at bay, yes I removed all the rust, got through several bottles of that kill rust stuff, that stuff that turns black, I've even Etch primed the metal, then several good layers of spray primer filler, then standard primer on that, followed by two layers of base green, then two layers of clear lacquer, it looks fab again but give it a year and I can see the rust coming back, it appears to be coming from the welded edge of the steel, how the sills look underneath, that pic is from the second run of cleaning off the rust & repaint. 

On my latest repaint I've pushed vinyl tubing up in the holes and forced engine oil inside, using a large syringe allowing the oil to run out everywhere, made a right mess but might stop the rust this time which i think is developing from the inside.

It’s weird how it’s developing from the inside out as I don’t get where the inside becomes exposed to water. I did see someone else on Facebook removed their front wheel arch liners and there was rust behind them. There’s quite a large gap at the front where the sill meets the front quarter panel so I’m wondering if water gets in there and travels down the sill? 

10 hours ago, rowly13 said:

Yeah the join from the inner arch panel to the very end of the outer sill where it turns 90 Deg towards the car. No seam sealer joining the 2 pieces together on mine. I expected to see it bonded instead but when I drilled out the spot welds there the piece of rusty steel just fell off, no sealer at all. Looked like it had all started from there, was less and less rusty the further away it got from that point.

Ah I think you’re talking about the flat bit where all the grit ends up sitting? No I don’t think mine has sealer either. It’s surprising really as it seems like the perfect place for salt and water to get in and start rusting. I just painted over the join to prevent any water ingress. I’ll also spray cavity wax from the inside to stop any rust there. 

36 minutes ago, JBOD said:

 I did see someone else on Facebook removed their front wheel arch liners and there was rust behind them.

These images isn't from my car[ebay pic] but obviously/maybe caused by stone chips but the rust has spread very heavily, even going under the lower body seal, I've also seen severe rust on the inside of the wings, hardly any primer on the wing at all, looking at the inner lower part of the wing it looks like a proper water trap.

Think I need to remove my front wheel arch liners & check before it's too late.

48 minutes ago, Ian Lanc said:

These images isn't from my car[ebay pic] but obviously/maybe caused by stone chips but the rust has spread very heavily, even going under the lower body seal, I've also seen severe rust on the inside of the wings, hardly any primer on the wing at all, looking at the inner lower part of the wing it looks like a proper water trap.

Think I need to remove my front wheel arch liners & check before it's too late.

I put mudflaps on mine when I got it about 3yrs ago and there was literally compost sitting where that rust is on the front wing. I think water from the window/ scuttle panel channels down there and takes leaves and stuff with it. 

2 hours ago, JBOD said:

I put mudflaps on mine when I got it about 3yrs ago and there was literally compost sitting where that rust is on the front wing. 

I hear you on the mudflap build up pal, I remove mine once a year and clean away the filth which has built up, shocking isn't it, this is our fiesta which I try to keep looking lovely,  I've more pics showing my grandson growing up, the back lights have been upgraded twice now and have the last LED upgraded brake lights fitted.

Is he growing or are you shrinking?  

14 hours ago, JBOD said:

Ah I think you’re talking about the flat bit where all the grit ends up sitting? No I don’t think mine has sealer either. It’s surprising really as it seems like the perfect place for salt and water to get in and start rusting. I just painted over the join to prevent any water ingress. I’ll also spray cavity wax from the inside to stop any rust there. 

Yeah I think we're on about the same bit. Did you give the outer sill a firm push with your thumb? Mine was noticeably 'spongy' at the rear before the repair. Even when the rust was cleaned away and it looked ok.

21 hours ago, TomsFocus said:

Is he growing or are you shrinking?  

Sat down on the last pic! 😂