Bodywork and chassis repair

Finding the rot, the biggest mistake made by people purchasing a 205 is by looking under the car at the floor pan, Peugeot coated the floor pan with a thick rubber seal, any rot in these areas would be only viable from the other side.

To correctly check a 205 or 309 for rot, the following items would be needed to be removed  headlights, carpet, rear clusters and the inner 3/4 plastic door panels, which I feel is the minium when purchasing a Peugeot.

Here are the most common areas that can be affected by rot

  • A and B pillars
  • Under the rear seats
  • Bulkhead /floor pan seam
  • Lower and front edges of doors
  • Boot floor
  • Floor pan around seating
  • Roof panel
  • Around and under windscreen
  • Lower rear quarter panels
  • Rear chassis panels around fuel tank
  • Boot floor to floor pan seam
  • Rear quarter panel behind rear cluster
  • Headlight front and front chassis legs panels

To see these areas more in detail click on this link


Thankfully there are panels still available for the 205 and 309, and for those that arn’t, PRD can fabricate from fresh, Please note I do no use slices or whatever the internet term is for cutting 30 year steel from doner vehicals.

My prices for such body/chassis work is £45 PH, regarding welding, this is £55 PH which to cover the extra insurance and consumables for such processes.

For rust prevention I like to use aqua steel, this is a rust converter/inhibitor but with the added benefit of sealing the surface from further moisture. I’ve used this for 12 years and has been faultless and never seen any rust work its self back through, the next protective coat is an etch zinc primer to ensure a proper long-lasting adhesion. To bond on panel or to seal seams I use tiger seal and for chassis protection, either Raptor or Gravitex.

Other than the front panels or any other general engine bay repairs via welding, all other repairs will require fuel tank and interior (carpet, under lay, seats and plastic trim) in the affected areas to be removed.

Rot/corrosion happens in area where moisture or heavy wetting areas happens, vehicles fitted with a sunroof are the most affected, due to the sunroof fitted with 4 rubber tubes to allow trapped water to escape, these run down the A and C pillars, but unfortunately these can become blocked or perish and so leak water in the rear chassis rails and rear portion behind rear light clusters.

The interior heater matrix is also a culprit to leak, which leads to rotting of the soundproofing and also bulkhead to ffloor pan seam.