Chassis filled with foam. Garage unable to repair corrosion due to fire risk.
 

Hello,

My Chrysler Voyager fourth generation failed the car inspection (MOT) this week as the garage found corrosion on the chassis.They explained it as "Integral body structure corroded to the extent that the rgidity of the assembly is significantly reduced nearside rear outer (sill)

When I asked the garage to repair, they found that under the corrosion was a void filled with foam. The foam made it dangerous to weld as the foam could catch fire. The did quote over 1000$ to "cut and clean " the chasis from foam to start repair the chassis from corrosion. I have attached pictures. What is your opinion? The garage had never seen a car filled with foam similar to my car.
https://cimg3.ibsrv.net/gimg/www.chr...a28ad24397.jpg
Corrosion rear side
https://cimg5.ibsrv.net/gimg/www.chr...9b2ad96f18.jpg
Whole identified by the garage as the insertion point for the foam
https://cimg6.ibsrv.net/gimg/www.chr...9f77917fcc.jpg
Void filled with foam. As the outer layer had corroded the garage cut it open and removed the foam. There are still traces of foam.
https://cimg7.ibsrv.net/gimg/www.chr...74df2266f4.jpg
Closer look at the corrosion on the rear side. After the garage had looked on the problem area.
https://cimg9.ibsrv.net/gimg/www.chr...03472bf456.jpg
Problem area of the car is the rear side

looks like someone has filled it with expanding building foam. the problem with that stuff is it sticks to everything and travels far. also quite hard too get off too. unless you know how much has been put into the chassis/bodywork. it could cost you a lot in having it cut out, also re-welded and sprayed/painted. a £/$1000 seems a lot of money, better too shop around and look for a few cheaper quotes. good luck with the car

chassis-stiffening
 

Thanks for your replay cheeseyrimmer1

It seems like filling the chassis with foam is a method used to stiffen the chassis.

https://www.timeattack.co.uk/chassis....l2D6tq7N.dpbs

i've not seen this method used before. its a pity it doesn't stop the rust, from eating the bodywork. if you can. try and get a large chunk of it out of your car. see if you can set the piece on fire. some foams are flame retardant. if it doesn't burn, you might be ok to weld it. all you can do is try. hope you get it sorted Henriklundgren