DeBruce

My subframe was rusty too and looked quite bad when the sill work was done but the guy said it was actually okay if you knocked off all the rusty top and rust-eater it. When he finished it seemed to come up okay to be honest and it was solid under the rust. Yours could be the same and just need a really good go at with a hammer, wire brush and rust eater. For me it was the sills that were the expensive bit but then the rest of the car seemed to be solid. Seems on these cars the sills by far take the brunt of rust issues. Personally I think your sills need doing even if the MoT guy passed it. As the other guy said, if you want to keep it long term you need to tackle this sooner rather than later.

Just posted this on a similar thread. I have literally just gone through this with my S-Type R 2002. I had similarly rusty sills and when the undertrays and skirts were removed it wasnt pretty. Its ended up costing me £2500 in metalwork having them replaced on both sides. There were three panels that come together and they had all started to rust badly. The sills are open at the ends so water gets in and rots them. I also have rust starting to show in the rear passenger door opening by the sill plate. I think if it's started to go, you are going to have to spend money on metalwork and welding pretty soon now if you want it to be solid and last. I'm based near Coventry, West Midlands and the guy that did my car is very good and I would recommend.

I have literally just gone through this with my S-Type R 2002. I had similarly rusty sills and when the undertrays and skirts were removed it wasnt pretty. Its ended up costing me £2500 in metalwork having them replaced on both sides. There were three panels that come together and they had all started to rust badly. The sills are open at the ends so water gets in and rots them. I also have rust starting to show in the rear passenger door opening by the sill plate. I think if it's started to go, you are going to have to spend money on metalwork and welding pretty soon now if you want it to be solid and last.