That's it - you beat me to it.

 

I have an '05 S with some major rust problems (rust coming through bottom of the driver door and driver side taillight and quarter panel). They denied the claim saying I had to specifically request a corrosion check when I brought it in for service. The dealer has been no help. Anybody else getting this BS from them?? Anyone take it any further (BBB, lawyer)?

 

Have you tried calling MINI USA yet? I think that would be the first step. I think the number is 866-ASK-MINI. This obviously should be covered under that rust warranty.

 

Yeah that's who I was on the phone with (forgot to mention that in the last post). They are the one's telling me all this.

 

Hey not sure why I never saw all these replies until today. Thanks.
I'm going to post a link to this thread on their FB page and if that doesn't work walk in with the TSB.

 

I had my pass door replaced under warranty due to rust, it hadn't perforated yet, but it was probably on it's way there, and probably why the replaced it.

If your car is under the rust warranty, take it in, even if it's not, take it in.

 

I wish they would cover the early years too, but I doubt they'll do anything if I take mine in. '03s only had a 6 year rust warranty...

My passenger door is definitely rusting from the inside out. I coated the inside with por15 last year which I'm hoping will prolong it's life by a decade or so...

 

saw some rust under the door seal and i also have water leak coming in the car wondering if seal is bad. will take it in to have it check wed.

 

took the mini in and they are gonna do the rust repair this week. they said they would replace carpet if they find anything under it.

 

Hey guys! I stumbled upon this thread and am having issues with the driver side of my 03' MCS having a drenched floor mat. I just bought the car used about a month ago from the owner who kept it garaged so he never noticed this but I'm guessing there may be rust just like you've discovered. However, my question is where is the water coming from, and can anyone tell me where to start or where to take it? I noticed my windshield is a replacement because it has the PPG logo instead of the Mini OEM logo. So either my leak is from a poorly installed windshield or maybe it's coming from the same place yours is? Help!

- RH

 

Don't know how many peeps have this issue, but worth taking out the tail lights to examine. Will keep you posted regards the repair, not looking forward to visit the body man.

 

I have a 2004 Mini Cooper S and I found a tiny little bit of rust on the right side of my hood (as if you're sitting in the car) right where the hood meets the bumper when the hood is closed. It's between the right headlight and the grille on the edge of the hood. Would this 12 year warranty cover that or is it just the door sill rust?

 

I've got paint bubbling in that same area on my 2006 MCS. Just below the tail lights on both sides. I made an appointment to have the car checked out at the dealer on Monday for this. In researching this issue I came across this thread - will have to look for the door sill rust tonight!

 

I'm starting to see a bit of door seal rust now after 10 years of the car driving in Minnesota and New York's salty winters. however it's nothing compared to the rust forming on my drivers door.

 

Hey I know this post is old. I'm dealing with the same issue and I can't remember if the weather strip lip (on the inner side) lays over the plastic interior molding or if you have to insert it into the molding. ANyone got a quick answer to this?

 

The rubber lip lays on top of the plastic interior molding on my car, and my sister's '06.

 

Thanks, akindimini!

 

Glad this old thread has been revived.

Just bought an 06 Cooper with 100,000 miles, showing a tiny amount of rust on the door sills, haven't found any rust anywhere else. Car is really clean, bought from the original owner.

Gonna keep it FOREVER.

So, I haven't read all of this thread so please forgive me if the answer is here somewhere.

I've had good luck on other cars with 'Krown' rustproofing, it's one of those oily/waxy treatments they spray inside all the panels and doors.

Bit messy but it has worked well for me in the past.

Is there any MINI particular reason NOT to use this approach to making our MINI last forever ?

 

My opinion - planned obsolescence. Make it last long enough so that it won't rot out for the original owner. Seems most people keep their cars 6-8 years, then move on.

People who tend to keep vehicles forever (or at least, until the wheels fall off) are a dying breed.

 

But do they use commercial rustproofing ? ?

 

Nearly every vehicle I've owned has been rustproofed (or undercoated). It's a must in the climate I live in. I was a bit hesitant on getting the MINI rustproofed due to concerns about voiding the 10yr/unlimited mileage corrosion warranty. So far, so good - not a speck of rust anywhere, even under the door sill area, inside the door cavities, and underneath the wheel well plastic panels. I am pretty **** about keeping areas w/ the potential for dirt/salt build-up clear of debris, though.

 

The area that rusted on my car was not an external part, it was literally where the outer door skin was welded/mated to the inner door skin. They treat all the parts, and when they took it all apart, they saw what looked like glove/finger prints where the assembler had smudged the rust proofing, then assembled it. That's how rust happened on my car.

 

SuprCoop - was the rust covered under warranty?

 

Mine was, yes, but I have an '05 with the extended coverage. Mine also happened on the door itself, not the sill. But rust is rust.

 

I have been meaning to write this up as my solution to this problem. My Mini is a '03, so when I found my rust, I was out of warranty. From my standpoint, as long as the rust is stopped, I am ok with it being there, since I dont look under my door seals much. This fix takes about 30 minutes. Get ISC Helicopter tape from www.findtape.com in the 2 inch X 12 foot roll (while you are at it, get some felt tape to attack all the rattles in your car). If you follow the pics, you will see what the result is. You first put the tape on the top edge then bend it over the seam- starting at the apex of the bend (after you have sanded and rust-stopped the metal). This tape also worked for sealing the seam at the rear tail light where the sealant fails and starts rust there. The tape is very sticky, pliable and I think will keep water and air from making its way to the paint at the pinch weld. Happy motoring.