Anyone else seeing rust on rear door seams?

[jeff kushner]

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]

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

 

[Flexpedition]

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]

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]

less than 19K

...on a 2004???

 

[bobmbx]

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

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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]

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]

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]

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]

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

 

[HawkX66]

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

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View attachment 31699

The Evaporust soak is a good idea, but it will come back. Unfortunately when you have it rusting through seams like that, it started under the seam where you can't get to unless you open it. You might get lucky and the Evaporust will get into the seam, but it's doubtful. High concentrate vinegar works well on rust also.

 

[cmiles97]

You have a 4 year old vehicle with rust showing? You didn't drive it that deep in the atlantic or other salt water source? Any 4 year old vehicle should not be rusty even driving the salt roads of NY during the winter. White does show rust if you have it. Mine is black and would be more difficult to see. It makes me sick to think 2 years from now I have to mitigate rust when other vehicles can go a decade before that happens in the same conditions.

Now I am seeing why Expeditions used values plummet.

 

[Don Hall]

less than 19K on a 2004???

Yeah, Trainmaster.....less than 19K on a 2004. Truck goes to Costco once a month, a few local trips,
and a rare trip out of town by a family member. At 87, I don't need to go anywhere. Walmart and Home Depot
ship all my needs to my home. Any trip out of town is in my vette (very rare).

 

[bobmbx]

Yeah, Trainmaster.....less than 19K on a 2004. Truck goes to Costco once a month, a few local trips,
and a rare trip out of town by a family member. At 87, I don't need to go anywhere. Walmart and Home Depot
ship all my needs to my home. Any trip out of town is in my vette (very rare).

87. And owns an Expedition and a Corvette. I think you win.

Tip O' the hat, Don.

 

[Langer]

87. And owns an Expedition and a Corvette. I think you win.

Tip O' the hat, Don.

AND 100 yards from Monterey Bay. The man has done life probably far better than the rest of us combined. Haha

 

[16plati]

Nothing on either of my 16s anywhere. I keep them looking newer than factory

 

[Jamo]

Don said 'Vette. He didn't say if it was a "Cor" or a "Che". I think I know the answer and I too will tip my hat to you Don...

 

[Don Hall]

Don said 'Vette. He didn't say if it was a "Cor" or a "Che". I think I know the answer and I too will tip my hat to you Don...

Thank you for the compliment, Jamo. ('92 - 67K miles -- NO RUST)

 

[jeff kushner]

Come on now, don't knock the "Che" <LMAO>....that little 1980 sh*tbox just ran, and ran, and ran and ran....365,000 miles on the original clutch, tranny, engine...AFTER teaching my wife to drive a stick in that very car at the dealer before I bought it!

Nope, not enough power to get into trouble though.....kind of like a Bug.....

Not meaning to diss my ancient(lol) friend Don though either......at 87, you drive what you have always wanted to...if you can.

I'm a firm believer in "if you can, you should" when it comes to fun. I took photo's when my Kerry's Dad came down and rode bikes with us. He rode her '73 CB350, she rode my '82 yammy turbo and I rode my DL1000. I had one blown up to poster size for each of them....he was your age yet playing like mine....kudo's my friend!



jeff

 

[Boostedbus]

Maybe take the door panels off and spray a rust neutralizer around the pinch welds from the inside. Seems like it would penetrate in between better.