Underseat (battery area), general rust...

The steel plate which in essence holds the battery was a bit rusty, inside and out, so I bashed it with a hammer and gave it all a coat of rust treatment, it is now a little thin, but solid enough.

Tomorrow I am going to give it a coat of hammerite which will hopefully keep it good for a while.

Is there anyway you can replace those bits or is it a big strip out job to get at them?

I have been sanding/grinding bits down and then attacking it with rust stuff and then red lead, but I am getting into some hard to reach areas now and can't help thinking theres got to be a better way, what do you think?

I am also going to attack all the box section with waxoil soon, any tips.

The army spray diesel all over there landys/trucks undersides at the end of each summer, what do you think of that, good idea or bad idea?

You could use glass fibre & resin to strengthen & protect the remaining metal on the box, especially as you've cleaned and painted it - messy but the fumes from the resin are worth it .

If you can get hold of some phosphoric acid it's worth rinsing the hollow sections through - as this will kill the rust and form a protective layer.

Get any welding repairs done before other treatments.

If you have a compressor, get some quality paint into the chasis before waxoyling it.

I think the the MOD use Dinitrol rather than Waxoil. http://www.dinitrol.co.uk/

i came accross similar prob when wanting to enlarge my 110 battery tray. i just cut out most of the base. left the front and back, did away with the angled part near the sill replaced it with some 4inch x 1/8inch thick galvanized angle i had an used a steel treadplate galvanized manhole cover as a base. just bolted it all together in place and sealed the joints with sikaflex. had a bit of a list to port after i'd fitted 2 110ah battries right enough! i' had my 110 for years an it had a lot of surface rust when i bought it. powerwashig and waxoyl stopped it dead.