Spotted a small bubble in the underseal on the LHS chassis under the wheel arch. Just behind the TC rod connection. Poked at it with a screwdriver with a nervous push and horror....through it went....into stale air.

So after removing the guard it gain real access, I poked some more. There is what seems to be a factory strenghting plate there (maybe there to strenghten the TC rod mount??). The reason I say factory is that the whole area shows no signs of damage, the paint is matched and the underseal has not been touched.

It was spot welded on and then underseal sprayed over it, got out the wire wheel to clean it up and IT turned up just fine, but it had holes in it. Anyway, I have removed all the plate as under it the metal was micro thin. I now will have a easy patch to put back in there but I put a double plate back in to be double sure.

Looking down the exposed inside of the chassis rail, I see fisholine everywhere with great looking metal. I also see a opaque (probably clear when new) plastic bung on the pasenger fire wall. Pulling up the carpet I see it there and wonder if it is also a factory standard item to inspect the chassis rail internals or a PO add on? Any ideas.

The whole area would have been rust free if at the factory they had not rushed to spot this plate in. There was a slight ripple in the front of the plate that water entered, and tracked down the panel to eat away merrily. So....check your Zed to see if you have the same little problem.

So I'm going to POR the entire internal rail before and after the plates are back in. The resto remains.

I think that little white cap was put there when the car got some sort of rust protection inhibitor sprayed in there.

2¢

Enrique