So it appears that the Tetroseal coating was a bad idea. Now to find a way to get it off again...

You will probably be ok, I guess a lot of the moans I've heard are from classic car owners who use it on thin sheet steel panels. So on a galv chassis, I don't reckon you need to bother getting it off (it would be a pig of a job involving a drum of turps). I bought some to use on my RRC sills and rear X-member but was warned off it. Like I said, on a chassis you should be ok. Just stick waxoyl in the cavity maybe?
 
I did think of sticking some thin aluminium plates over the holes into the cavity using tiger seal. Surely it's best to keep water out of there altogether?
 
I think those holes also act as air vents although the holes in the front outriggers which would get salt spray into them from the front wheels, I sealed with small grommets.
 
I think those holes also act as air vents although the holes in the front outriggers which would get salt spray into them from the front wheels, I sealed with small grommets.

you sealed them and now made a point for condensation to form and stay there, not a good choice
 
you sealed them and now made a point for condensation to form and stay there, not a good choice

There are holes in the rear of the outrigger which I have left open so shouldn't be any condensation issues. Just couldn't see the point in allowing salt water to be sprayed from the wheels into the front of the x member.
 
I think those holes also act as air vents although the holes in the front outriggers which would get salt spray into them from the front wheels, I sealed with small grommets.

There are holes in the rear of the outrigger which I have left open so shouldn't be any condensation issues. Just couldn't see the point in allowing salt water to be sprayed from the wheels into the front of the x member.

your quote you said you sealed out riggers with grommets. That is where you will get condensation, and get white rust.

Take any bottle with a screw top on tight put it outside for the day and night, look at the bottle next day you will see condensation in it, same as your outriggers will. Your chassis do what you want
 
Ok, for clarity, I sealed the two small holes in the front forward facing vertical face of the front bulkhead outriggers with grommets to prevent salt/ water spray from front wheels entering the outrigger. However, there are also two small holes in the rear facing vertical face of the bulkhead outrigger which are open. It is therefore not sealed and air can circulate and moisture evaporate.
Sorry for any confusion
 
rivnuts to hold the stays and protect the drilled holes beorehand, if youre dead against drilling rivet the stay to a small square plate and bond with araldite 2015, grat stuff its holding my rear tub together
 
It's been galved, i wouldn't worry about it. even if you poured water inside the chassis it would take bloody ages to rust. People have just left galved chassis untreated and had 15 years no issue. Only thing i'd be concerned about is the salt over winter damaging the galv, but the underseal has taken care of that.

I'd also just leave the underseal alone. If it starts to fall off then just wait, it'll either weather or you can twash it and then stick some more on.
 
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