Just seen this post and thought I'd post my method of underseal removal. I really struggled until I came up with the following:
You Will Need:
-Hot Air Gun
-Scraper
-Spray Bottle (something like an empty household cleaner bottle)
-White Spirit
-Wire Brush Attachment for drill
-Electric Drill
-Scourer
-Kitchen Towel
1) First, you start off by heating the area with the hot air gun and scraping with the scraper to get rid of the worst of the underseal. Don't worry if it all still looks quite messy.
2) Fill your spray bottle with white spirit and spray the area. This softens the remaining layer of underseal.
3) Use the wire brush attachment on the electric drill to go over the area. For tighter or more difficult to reach areas use the wire scourer and your gloved hands to scrape at the area. It'll all look even messier now.
4) Spray the area again with clean white spirit.
5) Simply wipe with kitchen towel and you'll have an underseal free surface!
Having my mini on it's side to remove the underseal made it a lot easier! It took me a few days to remove the underseal, spending a couple of hours per day. If you were a bit more determined the same job could easily have been done in a day.
