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[terry paget]

Thank you all for your advice and experience. I thought this particular car was destined to be always free of rust, but I was wrong. This MOT failure has set me back. After 20 years of providing Senators and Omegas for my family, that happy period is over. I now have 2 working Astras, and a Rover Streetwise that came with daughter-in-law. I prefer the big Vauxhalls though.

My other 2.5 estate is also due for MOT now. It seem all right to me, but I must check it out very thoroughly, especially behind the sill covers and rear wheel arch liners!

Fixed 

Thanks again, will do.

[terry paget]

I had checkd the brake pipes a year ago, looked good, I greased them. This tester knew where to look, he found 2 pipes in a bend LHS above the rear axle where I had not looked. If I wish to replace the rusty one, do I have to replace it all the way to the ABS unit, or can I connect a new pipe to the sound steel  pipe under the car?

[Doctor Gollum]

I had checkd the brake pipes a year ago, looked good, I greased them. This tester knew where to look, he found 2 pipes in a bend LHS above the rear axle where I had not looked. If I wish to replace the rusty one, do I have to replace it all the way to the ABS unit, or can I connect a new pipe to the sound steel  pipe under the car?

What else did it fail on?

[terry paget]

I had checkd the brake pipes a year ago, looked good, I greased them. This tester knew where to look, he found 2 pipes in a bend LHS above the rear axle where I had not looked. If I wish to replace the rusty one, do I have to replace it all the way to the ABS unit, or can I connect a new pipe to the sound steel  pipe under the car?

What else did it fail on?

Failed on 5 items.
Lambda outside specified limits
Major exhaust leak
Brake pipe excessively corrode offside (front ro rear)
nearside rear suspension component prescribed area corroded
offside                        ditto

I presume when they identify the car to the Boston emissions tester it also advises prescribed areas  to seek out and examine, and probably boxes they can tick to list failures.

[Doctor Gollum]

As you were... Thought this was an additional 2.5...

[terry paget]

Thank you all for your advice and experience. I thought this particular car was destined to be always free of rust, but I was wrong. This MOT failure has set me back. After 20 years of providing Senators and Omegas for my family, that happy period is over. I now have 2 working Astras, and a Rover Streetwise that came with daughter-in-law. I prefer the big Vauxhalls though.

My other 2.5 estate is also due for MOT now. It seem all right to me, but I must check it out very thoroughly, especially behind the sill covers and rear wheel arch liners!

Fixed 

Done. Left hand cill

Right hand cill

Right hand wheel arch

They look remarkably healthy to me.
 

[terry paget]

Apologies, rhight hand wheel arch of diffferent car. Here is V828 rear wheel arch:

[Doctor Gollum]

Now remove the covers from the rear end of the sills INSIDE the wheel arches. And if possible from your pit, look very closely at the areas where the triangular plates bolt on.

And report back 

[BazaJT]

Re the question on the front to rear brake pipe;yes you can buy a joint piece and use that as long as you have a pipe flaring tool that can be used in the area you're where the joint is.

[terry paget]

Re the question on the front to rear brake pipe;yes you can buy a joint piece and use that as long as you have a pipe flaring tool that can be used in the area you're where the joint is.

Can I use the flaring tool on the steel pipe?

[terry paget]

Now remove the covers from the rear end of the sills INSIDE the wheel arches. And if possible from your pit, look very closely at the areas where the triangular plates bolt on.

And report back 

Right front support bracket

Right rear

Left front

Left rear

[Doctor Gollum]

Struggling to see from the pictures what caused the failure :-/

[terry paget]

The recent pictures are of V828, the 1998 2.5 that has not yet been tested. X168, car that failed MOT, is my son's car. I am hoping V828 car will pass MOT when I submit it. The cills look good. My worry is the left hand catalyst, which rattles when punched. It passed 2 years in this state. Once again, I shall submit it rattling, and see how it fares. Last year it had an advisory about rust near the steering box.

Now that I better understand why cill corrosion warrants MOT failure I shall re-examine X168. Last year I had an Omega fail MOT with one of those brackets rusted through. That was beyond easy repair, car was scrapped.

[terry paget]

Here are all my remaining Omegas in happier days, 2016. The car in the background is 0E03, my other running Omega, ex-police manual 3.2, seriously rusty.

[BazaJT]

The flaring tool I have[bought some years ago off flea bay]was a pretty cheap affair,not top of the line or anything special,will do flares on steel,kunifer and copper pipe.I think[others will probably know better]that most flaring tools will do steel pipe.