It is a well known weak area of any year Geo Metro that the front frame horns rot out. This is the area where the tie rods come through and the front suspension mounts. This is what a good one should look like.
...and here's what mine looked like before I peeled back the undercoating.
...and after a bit more poking.....
This is a view from the back side of that same frame horn. Look how little metal was left supporting the lower control arm!
Patterns were cut from card stock [cereal boxes] and transferred to new steel.
After lots of grinding and no less than 6 hand cut pieces of steel were fitted and welded in.
Just before smoothing and priming.
Today I'm sanding bondo and might possibly have time to buff out what's left of the white paint.