While replacing the drivers side door cavity seal, I came across some rust staring at the door's threshold....it is where the pressed metal is spot welded together and the door cavity seals is pressed around it.

Prep is key as with any paint work. If you have an 02-06 MCS or up to 08 Convertible, it is a good place to check. And order a new door seal while your at it. My door opens and closes so much better now, like brand new.













Last week, this whole strip was rusty, but apparently the body shop I used only did half of it while replacing the rear quarter panel......

Don't use regular masking tape when doing body work...when paint gets onto it the regular stuff it will curl up on the edges. Need to use auto body paint shop grade masking tape. Most automotive shops carry it. Bit more but worth it.



After removing rust with heavy grit then finer grit, wipe area clean with some windex on a rag, then some denatured alcohol. Then a few coats of the rust reformer topped off with few coats of satin black paint with rust inhibitors.....Repeat for pass side.



It isn't pretty but then it doesn't have to be, the door cavity seal covers it up...you just want it to be effective.

This is the sort of stuff when checked and repaired properly has potential to save you thousands of dollars down the road...

 

Looks good raven, mines clean now, hopefully it stays that way for a bit.

 

What are some other spots to look out for?

I just saw a r53 with massive cancerous rot under one rear turn signal?

I'm not sure if I should be worried about some minor rust on my suspension. Exhaust might be rusted out sooner then later... (Love the salty new England winters)

 

On the hatch above license plate is also a known rust issue.

 

Yep, mines under review by MINI now for that location. Only spot on the car that has rust too.

 

I believe this was noted a while back. Looks like yours has it i a couple more spots. Thanks for posting the DIY

There was a Tech service about it.



http://www.motoringfile.com/2007/01/...oor-sill-rust/

http://motoringfile.com/files/doorsillrust.pdf



And of course the check under taillights and above the trunk lid grip.

https://www.northamericanmotoring.co...t-through.html

Thanks

 

but guess them fixing it is only till warranty runs out, even though it is a known problem???

 

well im glad I don't have that issue yet, just some superficial spots underneath the car currently, nuts and bolts, slight surface on control arms

 

hood at bottom of headlight opening. Have to remove headlight to expose the area.

Keep the door's tiny drain holes free of debris, bottom of door can be sketchy.

 

Just an update, have to do this to my 2012 R58 :(

https://www.northamericanmotoring.co...-minis-29.html

 

That totally sucks.
You'd think by then (for a 2012), they (BMW/MINI) would have resolved that known problem.

I also posted an update today, on that same "sticky link" about having to do some very minor new sil rust mitigation for the 3rd time on my '04 R53.
My previous repairs held up very well over the past 12years but this time; I proactively cleaned and neutralized small bits of rust particulates lodged withing the rubber channel as well as rechecking and cleaning out the weep holes in the rubber.

 

Yep, looks like its the same issues.