Rust :: door sill area of '02-'05 MINIs - Page 27 - North American Motoring

Stock Problems/Issues Discussions related to warranty related issues and repairs, or other problems with the OEM parts and software for MINI Cooper (R50), Cabrio (R52), and Cooper S (R53) MINIs.
Sponsored by:
Sponsored by:

Rust :: door sill area of '02-'05 MINIs

Thread Tools Search this Thread
Old 12-11-2013, 11:54 PM
yesti yesti is offline
5th Gear
Join Date: Jun 2012
Posts: 806
Thanks: 0
Thanked 6 Times in 6 Posts
I noticed both of my door sills have, at the least, surface rust under the rubber strip. 2012 Hardtop. Found it when I took it off to run wiring along the side of the car. Haven't done anything yet but dry it off after car washes.
Reply With Quote
Old 01-26-2014, 08:51 PM
PSA1's Avatar
PSA1 PSA1 is offline
2nd Gear
Join Date: Jan 2014
Location: Charlotte, NC
Posts: 65
Thanks: 0
Thanked 0 Times in 0 Posts
03 MCS rust issue fixed

Having just acquired an 03 MCS, I checked the sills as described in this thread and as expected found the dreaded rust! I promptly took both side apart and perform a relatively simple and effective repair. I will continue to monitor these areas now that I know they are an issue.

Here is a link to the work I did...


Last edited by PSA1; 01-26-2014 at 09:24 PM. Reason: add a few more pics
Reply With Quote
Old 02-25-2015, 08:50 PM
quicksilver2003 quicksilver2003 is offline
2nd Gear
Join Date: Dec 2014
Location: Canoe, BC
Posts: 56
Thanks: 0
Thanked 0 Times in 0 Posts
Confirmed with Mini/BMW Canada anyway. Warranty is 13 years for 2004 perforation, 6 years for 2003. So I'm up the creek with my '03, which has the exact same rust in the exact same spots as a 2004. Thanks Mini.
Reply With Quote
Old 04-19-2015, 10:26 AM
wedge07's Avatar
wedge07 wedge07 is offline
2nd Gear
Join Date: Feb 2015
Location: King George, VA
Posts: 70
Thanked 2 Times in 2 Posts

'03 MCS with the rust. I'd imagine the issue will present itself in all of the 1st Gen MINIs.
Reply With Quote
Old 04-23-2015, 10:02 PM
Filmy's Avatar
Filmy Filmy is offline
5th Gear
iTrader: (4)
Join Date: Apr 2011
Location: Valley Village, CA, 91607
Posts: 644
Thanked 7 Times in 7 Posts
Regarding the extended rust warranty: does anyone have a different TSB than this - SI M 41 02 06 ? My local Mini service department told me today that I was correct that this is a legit TSB and issue, but the TSB is only for "perforation", and I can't read/see the actual TSB anywhere.

Is there an updated TSB that covers flaking, but not yet perforation? My '04 is still covered but I have rust flakes and not perforation (yet). He was nice about it but he kinda blew me off, so if I want Mini to deal with this I'll have to do the legwork myself.
Reply With Quote
Old 04-26-2015, 06:18 AM
gestero's Avatar
gestero gestero is offline
2nd Gear
Join Date: Jan 2012
Location: Florida
Posts: 113
Thanks: 0
Thanked 0 Times in 0 Posts
I have a 2006 R 50 that had rust on both door sills but not very advanced. I used a drill with a wire wheel and removed the rust, then I use a product called "OSPHO".

Primed and Painted the door sills 3 years ago, the issue is no longer I keep an eye on both doors, spray occasionally with W-D 40.
Reply With Quote
Old 04-27-2015, 06:25 AM
Milpol Milpol is offline
2nd Gear
Join Date: Jun 2014
Location: Melbourne, Australia
Posts: 69
Thanks: 0
Thanked 0 Times in 0 Posts
I own a 2002 R50, it has rust on both doors AND the tailgate where the latch striker is.

A 1 hour drive to the dealership (time and fuel) to see if there is a possible Australian warranty on a 12yr+ car.

A 1 hour drive home (time and fuel) after making a booking if its covered under warranty.

A return journey back to the dealership IF its covered, Cost of Insurance for a loan vehicle to return home (more valuable time).

Return journey to take loan car back and pick up Mini after repairs IF covered by a warranty on a 12 yr old car (even more time)

So, with all the running around, petrol, time, negotiating work to be done (btw my time is important), wear and tear on the car.

A short trip to the local auto spares, 1 x wire wheel, 1 x roll of masking tape, 1 x small bottle of rust converter, 1 can of undercoat, 1 x can of touchup paint and the rest of the morning to wire brush the paint to clean bare metal, apply rust converter, apply undercoat, apply topcoat. Job done in under 4 hours and unless you pulled the rubber one would never know.

Satisfaction of a job that took under 4 hours compared to the hassle of running around, wear and tear and the petrol used let alone the time this would have taken on a 12 yr old car plus I got out of mowing the lawn ! Priceless and 100% satisfaction.

Lesson learnt, pull the rubbers occasionally and clean out the build-up of dust and grime and ensure its dry. Learn to maintain your vehicle and take pride you can do such a simple job. Its a lot easier than jumping up and down having a hissy fit or maybe your time isn't as valuable as mine. If the car was a couple of years old, I could understand it but on Gen 1's ! lets take a reality check.
Reply With Quote
Old 04-27-2015, 06:36 AM
americo11's Avatar
americo11 americo11 is offline
3rd Gear
Join Date: Feb 2015
Location: Rhode Island
Posts: 220
Thanks: 0
Thanked 0 Times in 0 Posts
I had to replace the rubber weather seal on my driver side when I got my car(used) it's a 2010 and there was none on the drivers side but a little starting on the passenger side. I noticed the passenger side because when it rains sometimes I get water ingress ,there was a post about after cleaning and painting I applied a bead of silicone to the pinch weld all the way along it to keep water from settling there again. Done!
Reply With Quote

Related Topics
Thread Thread Starter Forum Replies Last Post
FS:: NOVA: 2012 MINI JCW (factory) w/ 100k Warranty + TONS OF EXTRAS! igzekyativ MINIs & Minis for Sale 25 09-21-2016 05:38 PM
FS:: NOVA: 2013 MINI JCW (Factory) + Maintenance and Warranties igzekyativ MINIs & Minis for Sale 28 12-23-2015 11:36 AM
Door Arm Rest joedotmac R56 :: Hatch Talk (2007+) 8 08-28-2015 02:04 PM
FS:: Enkei NT03+M Wheels 17 X 7.5 -- Set of 4, New in Box Mini'mon MINI Parts for Sale 2 08-16-2015 05:15 PM
Airbag fault from removing headliner?? quality_sound R56 :: Hatch Talk (2007+) 4 08-07-2015 10:36 AM

Thread Tools Search this Thread
Search this Thread:

Advanced Search

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off

Forum Jump

All times are GMT -7. The time now is 04:18 PM.

North American Motoring is an independently operated web site supporting MINI owners and enthusiastsworldwide. As such it has no official relationship with MINI USA, BMW AG, or BMW of North America.All original artwork and design is Copyright © 2002-2004 North American Motoring. We are a participant in the Amazon Services LLC Associates Program, an affiliate advertising program designed to provide a means for us to earn fees by linking to and affiliated sites.