The corrosion starts from the inner side of the metal, behind the wheel arch liner: the mud settling there and the absorbent foam seal hold the water against the metal. From outside only blistering paint shows for a long time, while underneath it can already be rusted through. The sill and the jacking point fail the same way: that already fails the roadworthiness test, and it is dangerous when changing a wheel.
What to check
- Pull the plastic wheel arch liner aside and feel along the metal behind it
- Press the sill and the jacking points: if it dents or crunches, it is rusted through
- Check suspect patches with a magnet: under thick filler it does not stick