Hey Brian
<haven't been on here in a while, Steve pointed me to your thread>
I am in the same boat - my '5 died of rust in the arches and sills. Being a yellow-reg all its life, it saw more than its fair share of salt. Then one final fling on the beach in Galway signed its fate. I bought repair panels (MX5parts) and gave them to a welder in Leixlip to cut, weld and paint. EUR500 later, the car looked fine and went well. Got through its MOT and all happy. Until the rear arches started to bubble and bulge. The welder had just patched ontop of the old rust :-/ So the '5 has been off-the-road the past couple of years - it's been parted out, I sold the turbo etc and was going to scrap the thing but... my heart wouldn't let me do it, so it's sitting waiting for a Car SOS type intervention.
Plus the fact that my main car, an XK8 is such an epic machine (I use that word 'epic' with prejudice), such a fantastic car with speed, noise and personality. If it was convertible and manual, it would tick all boxes, but as a coupe it's great. Anyway, its rear arches started to bubble and bulge, and the nearside sill started to crumble. Again, the salt problem. So last week I left it with a different welder (reactivewelding.com) and got the car back last Sunday.
EUR450 later, it looked fine to the eyes, all the shapes were there despite it just being painted in primer. Until I went to sand back the paint last night ready to put a skim of filler on and some topcoat... cue the crunchy noise of metal-over-rust. So I took a cutter and some pliers to the patches and peeled them back. Rust. The patches weren't even welded to the inner wing, just folder over. So I will have to get a refund on the welding (it was cash in hand, wish me luck).
What I am left with is to either find some other randomer to do the welding or else to do it myself. I have been looking at this device - it's pricey, but how often does one buy such things ? Should be good for 10 years.
http://www.wholesaleweldingsupplies.ie/ ... ct_id=3285