Thanks for all the feedback on this 1 lads!! still not 100% sure what to as I plan to fully seam weld car,re-jig the cage and few other bits in Winter..It is time to get use out of the car now
For a competition car, what about just doing everything?
Cage, seam weld and fill the sill and chassis cavities with foam
As long as the chassis was clean and no rusty or other debris inside the cavities, I don't see how it could cause any problem with rust etc.
If the shell was dipped and then filled with foam where needed, it would be the right job!!!