[sridhga]

Recently, I bumped into an engineer in our office car parking. This engineer monitors Assembly and paint shops of our factory that makes compressor equipment. During our conversation I noticed bad rust on a nearby Maruti Zen car. I asked him questions on rusting. I also showed him two Palios in our office compound that were rusting. He showed me the nature of paint on that zen car and explained to me that it is of inferior quality. He asked me to look closely at the paint and that of a nearby Honda City and a Santro. I remarked that Santro's paint seems to be superior in quality than that of the City and both are better than that of Zen to which he agreed. He further stated that metallic paints are generally superior, and, further by close inspection of the paint, you get to know the quality of painting. Ofcourse it does need some practice to tell this. But I think people who look for second hand cars must pick this skill. Why just second hand cars? When you are putting your hard earned money in a car you got to understand that the manufacturer has taken enough care in building the car. The engineer colleague further told me that other than paint, what matters is the metal quality used. If the surface itself could be so bad, how can one talk of things inside the engine bay? I do not know if the anti rust treatment promoted by the shops is worthy of it. If it is so why are the manufacturers not doing is by default? I recently noticed rust on the silencer of my one year old Honda Activa. Let us talk about the kind of steel etc and paint to aviod rusting, and manufacturing and maintenance practices. Let us discuss companies that have good manufacturing practices to avoid corrosion.

[Sudipto-S-Team]

There are a few issues related to corrosion in cars. The place where the car is driven plays a major role. Nearer the sea is more dangerous. Regarding quality of paint on a new car - everything is built to a price and companies do a give some here take some from there kind of jugglery when it comes to such issues.
I must add that new environmental norms for paints is forcing auto companies to compromise on paint quality.
Teflon coating on a new car saves one a lot of brown stains down the line.
Meanwhile, here is a link to some gyan on automotive paint technology DuPont Automotive: Paint & Coatings for Metal Exterior

[Khandelwal]

Good topic.

One of my friend's Indica has also develped small cracks at various parts of the car body and is rusting.
Some of the visible places where there is rust on his car are, near the rubber beading on the rear windshield, inside of passenger door next to the driver.
He complained this to TASC and they said this is just one of the bad pieces that may have been produced - nothing can be done about it.
The car is just 3 years old and my friend is now thinking to upgrade to Dzire.

[Tejas@perioimpl]

I think if the cars are baked well during the paint process at the company, there shouldn't be a problem.

[NRIturbo]

places on a car where water can sit for a long time will generally tend to form rust. salt is a given, but I can't see salt going near any cars in India. Major reason would be oxidation on the surface of the car. So if anything wipe down the car, keep it clean, and if you like spray some WD-40 in areas known to rust and you should be fine.

[sgiitk]

By and large vehicles come with more than adequate anti-corrosion treatment from the factory. However, if you are in harsh weather location - coastal or very heavy rainfall area then additional treatment like Dinitrol may be advisable.

[deepclutch]

My 2002(2nd hand) indica DLE's underside was rusted with few holes even in the passenger cabin underside!.Currently ,completing the patch work.I suffered a big loss buying this used car.I or even my mechanic cannot expect this part of the car being rusted beyond imagination!When we checked ,the body is in very good condition -EXCEPT for the underside!

Anyways ,recovering from the losses.Seems the car was before used extensively near Mangalapuram(coastal) area hence the deep rusting.Hopefully ,I will use this car for 3 more years as I cannot afford a new car now.Currently Reworking the car to Top Condition Possible-even did a Engine Overhaul as well.
I was right by doing underside coating during every monsoon for our earlier car.

[Raccoon]

Originally Posted by sgiitk

By and large vehicles come with more than adequate anti-corrosion treatment from the factory. However, if you are in harsh weather location - coastal or very heavy rainfall area then additional treatment like Dinitrol may be advisable.

This is most certainly not true... the simple proof of this is that the results are far less than acceptable. I'v seen cases of premature rusting in 2 wheelers and four wheelers alike in a non coastal city like Poona! Areas most prone to rust seem to be the undersides of metal mud guards in 2 wheelers, joints and welds, fuel tanks, chrome platings, and silencers of both 2 and 4 wheelers and undersides of 4 wheelers. Some makes seem much more corossion resistant than others. Its pretty clear that this area does not seem to be given too much thought by many manufacturers. On the other hand, its likely they do this deliberately, so that they can sell more spares.

This factor should be given due consideration by vehicle buyers, before making new purchases.

[gpa]

Originally Posted by Raccoon

This is most certainly not true.....This factor should be given due consideration by vehicle buyers, before making new purchases.

You are right, though manufacturers claim that there is adequate protection from rust, even a light scrape of the underbody or running boards leads to start of fine rusting. If not taken care of this will eventually spread and become worse.

Recently a friend of mine who has an A-Star noticed that the underbody had a few spots of rust where it had touched a speed breaker a few months ago. The car is just a few months old. Promptly, he did a 3M underbody rust treatment and culled the problem in its roots.

[Raccoon]

^^^ Well, exposed metal can be somewhat excused for catching rust. However, a lot also depends on the type of metal used, etc, etc... hence I use the word "somewhat".

But what about surfaces that have some form of protection on them? I'v seen almost brand new bikes with spots/patches of rust on joints, etc.

My 1st Hero Honda developed loads of rust under its metal mudguards in just one monsoon. The petrol tank corroded from the inside. Chrome plating on one of the rims also peeled off! Yes HH did change those parts for free, even when my bike was out of warranty, but then it should not have happened in the 1st place! Also, the replaced parts, most likely of the same quality will start rusting again. Luckily, I sold that bike... so never found out. On cars also... some seem to be much more prone to rust. Indicas for eg. seem more prone to it.

Since rust is something that is observed mostly over time, most manufacturers don't seem to consider this to be a critical issue. And customers also seem to ignore this aspect. Ever heard of this being a consideration before anybody made an automobile purchase?

[Abeer]

Originally Posted by Khandelwal

Good topic.

Some of the visible places where there is rust on his car are, near the rubber beading on the rear windshield, inside of passenger door next to the driver.

Exactly same problem in my 2008 Hyundai Accent which is in extended warranty now.
I had called up Hyundai customer care number and then their dealer called me.
I visited Hyundai Service Center near to my place and they told me that rusting is not covered in Extended warranty and they would charge me around 6K to repair this.
He also mentioned that since I am their old customer, they would give me a 50% discount.
To remove the rust that is near the rear windshield, he mentioned that they would have to remove the same and then clean out the rust and then do some polishing and touch up before putting the rear windshield back. He also mentioned that this would require the rubber beading to be replaced.

The questions that come up are
1) Is rusting of parts not covered under extended warranty?
2) Old customer loyalty aside, how is that they agreed for a 50% discount even before I argued with them.
3) Apart from using Hyundai services, what are my other options?

I will post the photos by tomorrow as I did not get an option to click them due to the rains.

[diyguy]

My 2006 Swift Zxi has extensive rusting on the front passenger side around the beading around the window. So far I have done nothing about it.

[Thad E Ginathom]

Problems with rust on my 3-yr-old Swift VDI.

This is like it used to be over forty years ago in UK. Is India really that far behind?

[GTO]

Do modern cars still rust? I live right on the ocean and all of my cars are parked outside (save for the Jeep). Yet, in the last 10 years, I haven't had any corrosion problems with the Esteem, Zen, Lancer, C Class, Indigo or the OHC Vtec. Sure, I'm not talking about a small corner of some panel rusting after 8 years of usage...that's obvious. But I really haven't had any significant problem with rust that required a visit to the body shop.

Of course, Mahindra's shoddy build quality and the Jeep are entirely another matter. Do whatever you want, she'll find a way to flirt with rust.

Few exceptions like the Swift and Maruti's poor quality control. I've noticed the driver's door of my sister's Swift (3 years old) suffering from heavy corrosion.

[e4gleeyez]

@GTO I am sure that you are taking extra care of your rides and would like to know the same from you

NRITurbo talked about using WD-40, what is it and how should we use it?

Any other options available in the market to treat rusting on our own?