Anyone else seeing rust on rear door seams?

jeff kushner · Aug 20, 2019

We got back from vacation Saturday and Sunday we washed my truck....ok, for the first time in well over a year(it's a truck). Anyway I found that overall the paint is holding up extremely well. 2 road nicks in 73,000 miles isn't bad. I don't count my "operator-errors" like rubbing against the canopy I park under.

I also found this rust condition on both rear doors only. We all know how this is going to go if it's not addressed but I wanted to reach out to see if anyone else is seeing this in the 15-17 models?

My plan is to wet a paper towel or this strip of cloth with Evaporust, letting it soak into the seam....then painting with clear poly once the rust is neutralized. Any other ideas(I'm an engine guy, not a body man)?

jeff

JExpedition07 · Aug 20, 2019

No rust like that on my ‘07 (New York) for reference. It did need rocker panels replaced though.

Flexpedition · Aug 20, 2019

I have a Ford Fusion doing this on the front door seams, same exact spot. Rears are perfect. Evidently its a known-issue with 2nd gen, 2013 and newer Fusions and Lincoln MKZs.

The rust is coming from the inside -> out. So what you are seeing is the end result of whats going on inside the door. Any treatments or repairs you do to the result will be temporary until the root cause is addressed.

Don Hall · Aug 20, 2019

Only rust on my '04 was an 8" patch in the roof front 10" above the windshield. No reason why. Vehicle is parked outside, and we live 100 yds. from Monterey Bay.
Mileage is low, less than 19K, but that should have no bearing on rust.

Trainmaster · Aug 20, 2019

less than 19K

...on a 2004???

bobmbx · Aug 21, 2019

jeff kushner said:
We got back from vacation Saturday and Sunday we washed my truck....ok, for the first time in well over a year(it's a truck). Anyway I found that overall the paint is holding up extremely well. 2 road nicks in 73,000 miles isn't bad. I don't count my "operator-errors" like rubbing against the canopy I park under.

I also found this rust condition on both rear doors only. We all know how this is going to go if it's not addressed but I wanted to reach out to see if anyone else is seeing this in the 15-17 models?

My plan is to wet a paper towel or this strip of cloth with Evaporust, letting it soak into the seam....then painting with clear poly once the rust is neutralized. Any other ideas(I'm an engine guy, not a body man)?

jeff

View attachment 31698

View attachment 31699

You'll need to remove the existing corrosion down to bare metal. I'd use a a Dremel with a small wire brush to keep the worked area as small as possible. Prime with Rustoleum, then paint. You can probably get a rattle can to match. This assumes the corrosion is oxidation, and not electrolytic. The brown "rusty" color indicates oxidation.

bobmbx · Aug 21, 2019

Flexpedition said:
I have a Ford Fusion doing this on the front door seams, same exact spot. Rears are perfect. Evidently its a known-issue with 2nd gen, 2013 and newer Fusions and Lincoln MKZs.

The rust is coming from the inside -> out. So what you are seeing is the end result of whats going on inside the door. Any treatments or repairs you do to the result will be temporary until the root cause is addressed.

This probably has more to do with the poor application of primer/paint by the automated sprayers. They just follow a pattern thats programmed. If the initial pattern doesn't adequately coat certain areas, like edges and seems, you'll see the same rusty area on the entire model line, or at least every panel painted by that program.

TobyU · Aug 21, 2019

I would try cleaning well with the iron remover stuff for paint. Iron X is one brand.
Then a cleaner wax, then a hard paste wax coating. Then keep an eye on it.
I see no bubbling or lifting. Looks like just a collection area.

Plati · Aug 21, 2019

If its rusting from the inside out, like rocker panels do ... Can fix the outside all you want and the rust will persist? Nothing like that on my 2003 or 2014.

jeff kushner · Aug 21, 2019

I appreciate the responses guys. I'm hoping the evaporust, which is thin like water will leach into & under the seam when I apply heat from a hairdryer to pull it in via capillary attraction. Hopefully this will work as well as flowing solder or brazing metal does.

Since I build two stroke engines, I have a collection of porting tools and dremals so yes, the wire brush would be best b4 re-painting.

jeff

Anyone else seeing rust on rear door seams?

jeff kushner

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