Anyone else had RUST!

karl_683 · 24th September 2008, 08:03

I'm wondering if anyone else has had a similar problem to me. Around the rubbers where the wires enter the rear passenger doors there was a fairly large area where the paint was bubbling and rust spots coming through. The metal underneath was solid so I just stripped the surface rust off to repaint it, however after all the corroded stuff was removed the area was still all lumpy n bumpy. This was back to the bare metal so it looks as if the casting was poor. I would like to ask if anybody else has had this or if anyone has noticed bad casting?

Thanks, Karl

JohnDotCom · 24th September 2008, 09:09

Any chance of Photos?

karl_683 · 24th September 2008, 09:27

I might have some on my phone, they'll be rubbish though!

Mike · 24th September 2008, 11:17

Yes these are a known weak spot though it isn't a consistent problem area across all cars.

I have a suspicion that the cause may have something to do with tech's using metal or hard edges to reseat the rubber cable carriers/seals following ICE maintenance or other re-wiring work (or the seals being shoved in at build!). These seals are designed to be inserted from inside the door cavity only and its a hell of a job to do it successfully from the outside - daft design imo.

If the seals aren't properly seated or reseated then water gets in and corrosion starts.

I had this issue three years ago so 'persuaded' the dealer to strip and repaint. Since then they get a liberal dose of waxoyl or similar (inside the door as well as outside) regularly and, although not totally rust spot free, there is no growth.

Anyone working on these then my advice would be to remove the door card and reseat the seal from the inside thus ensuring a proper fit and no paint scrapes or removal.

I have some pics and will try to post later.

hth

karl_683 · 24th September 2008, 12:23

Found a pic of the area, as i said quality is not good! Didn't take the door card out to replace the seal, got it back in ok but shall be liberal with rust protection in future.

JohnDotCom · 24th September 2008, 12:36

Looks like it needs a bit of treatment to stop it spreading further.
Waxoyl on inside of door would help also IMHO.
Must have a look at mine before leaving for home.

STUBIE · 24th September 2008, 17:41

What year Karl

And I see your in Peterborough- Hello

Rob75 · 24th September 2008, 21:26

where the doors on the mk1 75 waxoiled from factory?
i only ask because when i took my door cards off the other day the inside of the doors seemed to be plasterd in the stuff!

ooh yeah and sorry for the spam.

karl_683 · 25th September 2008, 07:59

Thanks everyone for replying. This is one of the best forums out there. I can't imagine there's a place like this for VW Passat owners!

Stubie its a year 2000 on a W plate. Nice to see someone else from Peterborough on here!:lol:

Tim_Burgess · 25th September 2008, 08:56

My 2001 Y plate is rust free. But to my knowledge it's never been in a major accident, nor pulled apart to fit speakers etc.

In my experience, Mike is right - once people start taking things apart (especially those without specialist knowledge of the vehicle) either to fit accessories or at bodyshops it's a recipe for rot to get a hold.

24th September 2008, 08:03	#1
karl_683 Loves to post Jaguar X-Type Join Date: Jul 2008 Location: Peterborough Posts: 323 Thanks: 0 Thanked 0 Times in 0 Posts	Anyone else had RUST! I'm wondering if anyone else has had a similar problem to me. Around the rubbers where the wires enter the rear passenger doors there was a fairly large area where the paint was bubbling and rust spots coming through. The metal underneath was solid so I just stripped the surface rust off to repaint it, however after all the corroded stuff was removed the area was still all lumpy n bumpy. This was back to the bare metal so it looks as if the casting was poor. I would like to ask if anybody else has had this or if anyone has noticed bad casting? Thanks, Karl

24th September 2008, 11:17	#4
Mike This is my second home Rover 75 V8 Join Date: Oct 2006 Posts: 3,448 Thanks: 0 Thanked 206 Times in 32 Posts	Yes these are a known weak spot though it isn't a consistent problem area across all cars. I have a suspicion that the cause may have something to do with tech's using metal or hard edges to reseat the rubber cable carriers/seals following ICE maintenance or other re-wiring work (or the seals being shoved in at build!). These seals are designed to be inserted from inside the door cavity only and its a hell of a job to do it successfully from the outside - daft design imo. If the seals aren't properly seated or reseated then water gets in and corrosion starts. I had this issue three years ago so 'persuaded' the dealer to strip and repaint. Since then they get a liberal dose of waxoyl or similar (inside the door as well as outside) regularly and, although not totally rust spot free, there is no growth. Anyone working on these then my advice would be to remove the door card and reseat the seal from the inside thus ensuring a proper fit and no paint scrapes or removal. I have some pics and will try to post later. hth __________________ Mike [SIGPIC][/SIGPIC]

24th September 2008, 21:26	#8
Rob75 Gets stuck in Jaguar Join Date: May 2008 Location: wellington, somerset Posts: 905 Thanks: 0 Thanked 0 Times in 0 Posts	where the doors on the mk1 75 waxoiled from factory? i only ask because when i took my door cards off the other day the inside of the doors seemed to be plasterd in the stuff! ooh yeah and sorry for the spam. __________________ [SIGPIC][/SIGPIC]

25th September 2008, 08:56	#10
Tim_Burgess This is my second home 1999 75 Connoisseur SE 2.5, 2000 75 Classic SE 2.0, 2012 Lancia Delta 3, 2016 Dacia Sandero Ambiance Join Date: Jan 2007 Location: Kilcreggan Posts: 3,191 Thanks: 334 Thanked 334 Times in 162 Posts	My 2001 Y plate is rust free. But to my knowledge it's never been in a major accident, nor pulled apart to fit speakers etc. In my experience, Mike is right - once people start taking things apart (especially those without specialist knowledge of the vehicle) either to fit accessories or at bodyshops it's a recipe for rot to get a hold. __________________ *The fact there's a highway to hell and only a stairway to heaven says a lot about anticipated traffic numbers.*.

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24th September 2008, 09:09	#2
JohnDotCom * Rover 75 FaceLift Tourer CDTi 170BHP Auto ConnSE 2005 Model Starlight Silver Join Date: Nov 2006 Location: Abergele Posts: 28,735 Thanks: 0 Thanked 6 Times in 5 Posts	Any chance of Photos?

24th September 2008, 09:27	#3
karl_683 Loves to post Jaguar X-Type Join Date: Jul 2008 Location: Peterborough Posts: 323 Thanks: 0 Thanked 0 Times in 0 Posts	I might have some on my phone, they'll be rubbish though!

24th September 2008, 12:36	#6
JohnDotCom * Rover 75 FaceLift Tourer CDTi 170BHP Auto ConnSE 2005 Model Starlight Silver Join Date: Nov 2006 Location: Abergele Posts: 28,735 Thanks: 0 Thanked 6 Times in 5 Posts	Looks like it needs a bit of treatment to stop it spreading further. Waxoyl on inside of door would help also IMHO. Must have a look at mine before leaving for home.

24th September 2008, 17:41	#7
STUBIE This is my second home Back in a Rover Join Date: Nov 2006 Location: Peterborough Posts: 4,926 Thanks: 131 Thanked 357 Times in 261 Posts	What year Karl And I see your in Peterborough- Hello

25th September 2008, 07:59	#9
karl_683 Loves to post Jaguar X-Type Join Date: Jul 2008 Location: Peterborough Posts: 323 Thanks: 0 Thanked 0 Times in 0 Posts	Thanks everyone for replying. This is one of the best forums out there. I can't imagine there's a place like this for VW Passat owners! Stubie its a year 2000 on a W plate. Nice to see someone else from Peterborough on here!:lol: