Mike Sanders grease and then heatgun on the seam; it becomes waterlike, and flows realy well.Well unfortunately I am one of those lying on my back on the drive fixing it types. I would really like to be one of those fix it on a ramp types, but I ain't got that facility.
As soon as the weather is good enough I will be replacing my rear crossmember. I know long term a chassis swap will be required, but for now, patching is my way forward.
I have been lucky enough to be given a used rear crossmember. It is galvanised and in good condition. I have had to prep it for fitting and that required me to remove the old chassis sections from it.
After seeing how the chassis is manufactured it is no wonder they rust from the inside out. It is full of water traps and as such I think any treatment for the inside needs to be thin enough to allow it to flow easily into these places - I think anything thick or waxy may struggle to penetrate to where it needs to be.
View attachment 362901
You can see the overlaps here on this section I removed. This section is from the area just inside the extensions on a replacement crossmember. I think anything that can get between those skins needs to flow like water. I think it will also have to be injected well and be in sufficient quantities to get everywhere - I can see a few drips coming out so lots of tarps and cardboard required to save from bollockings from the boss!
When I cut my old crossmember off I will be inspecting the inside as best I can for an assessment of how long I think I have left!!
If anyone has recommendations for a suitable fluid for inside the chassis and which applicators are reasonable please mention it here with links if possible. I think myself and the OP would benefit from your experience and knowledge.
Thanks in advance for your help.
Mick