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Rust on bottom of front doors :(

Discussion in 'A3/S3/Sportback (8P Chassis)' started by V6Pete, May 19, 2010.

  1. V6Pete
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    V6Pete Now running on Bentley's y'all

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    [May 19, 2010]
    Whilst my car was being treated to d2detail today, we noticed some rust on the bottom of the front doors.

    Is this a common problem on the A3, and has anybody else had this?

    The car has FASH, so I'll be taking it down to Northampton Audi on Friday for them to send a claim over to Audi UK under the anti-corrosion warranty. I certainly didn't expect that on a 6 year old Audi...
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  3. PaulAr
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    PaulAr S3 (8P)

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    [May 19, 2010]
    Have they ever been painted, AUDI approved shop or otherwise?
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  4. V6Pete
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    V6Pete Now running on Bentley's y'all

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    [May 19, 2010]
    Hmmm, good question, 1 definitely not, 1 maybe... but the rust is visible on the inside of the doors where there hasn't been paint, so definitely an issue with the galvanising rather than with bad paintwork.
    #3
  5. PaulAr
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    PaulAr S3 (8P)

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    [May 19, 2010]
    Right Ok mmmmm, ...a starting point would be to do a DFT check (dry film thickness) on offending panels, think the gadget is an elcometer?. If they have been painted then the values will be a lot higher than areas that probably have never been painted, such as the roof, which you can use for comparison.

    Does sound odd that its on the inside though.
    What about rubbage on a mis alligned seal or door causing the paint to be breached? The doors have a habit of dropping on these things.

    FWIW I had rust problems with a 30month old MK5 Golf!
    It had some paintwork by an approved shop so it was down to them to fix it. Some knacker had rubbed to bare metal around the edges of the panel when prepping so these areas werent properly treated pre paint.
    Up shot was rust after 6months in the from of bubbles coming into the `good paint` from the leading edges of the bonnet and tailgate.

    Any pics?

    Good luck in the meantime:thumbsup:

    Paul
    #4
  6. paddy
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    paddy Audi=No fault code, no idea

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    [May 19, 2010]
    Cant see Audi being interested in a bit of surface rust on a 6 year old car Pete...

    when it rains the doors fill up with water...at least mine do. park it on a up hill slope and it poors out the drain holes in the bottom of the door when you open it . Make sure yours are clear ?
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  7. V6Pete
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    V6Pete Now running on Bentley's y'all

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    [May 19, 2010]
    Cheers for the comments - from what I can see, the issue on the outside is due to water and **** being caught between the door panel and the plastic trim at the bottom of the doors - that explains the rust on the outside. As for the inside, there's no rubbage on the sills, so don't think it's an alignment issue.

    I'll try to get some pics tomorrow, and will see what Audi say on Friday. The only good thing is they're usually f*cking useless, so hopefully won't put anything in the report to Audi UK to say it shouldn't be covered. From what the dealer said, it's nothing to do with them, they have to leave Audi UK to make the decision.

    It has a 10 (or is it 12?) year anti corrosion warranty. If it has FASH, and it's a defect, then it should be covered. Obviously they'll try to wriggle out of it, but I will kick off if they do...
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  8. paddy
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    paddy Audi=No fault code, no idea

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    [May 19, 2010]
    I think they will claim its an anti perforation warranty. Give em hell Pete :)
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  9. PH1L
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    PH1L Gievf Buckets VCDS Map User

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    [May 19, 2010]
    its a common problem, theyve revised the trim to sop it stand your ground and youll get it cleared on warrenty i got some of mine cleared but got fed up arguing for ***** service, car wasnt sealed properly so most of the underside had tiny bubbles, i stripped the car and got it painted while i was in hospital off my own back
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  10. PH1L
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    PH1L Gievf Buckets VCDS Map User

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    [May 19, 2010]
    fyi im pretty sure its 10 yr corrosion warrenty and dont let them tell you its due to a chip i almost booted the **** that was inspecting the paintwork. if audi arent playing ball get a local bodyshop to inspect it for you and do a little letter for you to go back up with
    #9
  11. V6Pete
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    V6Pete Now running on Bentley's y'all

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    [May 19, 2010]
    I'll burn the f*cking dealership down then.
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  12. V6Pete
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    V6Pete Now running on Bentley's y'all

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    [May 19, 2010]
    It's definitely not a chip... I know a very good independent bodyshop, and they'll be happy to give an honest independent opinion.

    That certainly helps to know - although speaking to Audi, they always like to deny that revising parts is an admission that the previous design was ****! It's clearly a design fault, so won't give up without a fight.
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  13. Khufu
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    Khufu Active Member

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    [May 19, 2010]
    mine are both doing it at the screw. Somebody said it could be to do with the type of metal the screws are made of reacting to the galvanzing?
    #12
  14. V6Pete
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    V6Pete Now running on Bentley's y'all

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    [May 19, 2010]
    You wouldn't think building cars was as hard work as Audi make it look....
    #13
  15. paddy
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    paddy Audi=No fault code, no idea

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    [May 19, 2010]
    LOL Pete..You know i took mine back Monday..well rang them today and they haven't touched it yet...I dont think Audi is the problem, its **** franchises.
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  16. Sarah's A3
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    Sarah's A3 MODERATOR V6 S3 Hybrid Staff Member Moderator

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    [May 19, 2010]
    Mine has some rust on the rear passenger wheel arch about an inch long! I'll have to get this looked at too!
    #15
  17. PaulAr
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    PaulAr S3 (8P)

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    [May 19, 2010]
    A dirty protest first though :yes:
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  18. paddy
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    paddy Audi=No fault code, no idea

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    [May 19, 2010]
    Dont burn Audi Guildford down Pete !! or at least give me some warning :)
    #17
  19. V6Pete
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    V6Pete Now running on Bentley's y'all

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    [May 19, 2010]
    Come off it, you'd be very happy to get an insurance pay-out surely?
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  20. PH1L
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    PH1L Gievf Buckets VCDS Map User

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    [May 19, 2010]
    too true get rid of the riddled 3.2 and buy the real s3
    #19
  21. S3EDDIE
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    S3EDDIE Member

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    [May 26, 2010]
    Mines been in three times. First time to get the bottom half of drivers door done due to small rust bubble, second time was to repair the rust in the apperture for the passenger door handle and the last time was for them to do the door handle again. Bloke at the bodyshop who did the repairs says that the metal they use is all re claimed stuff these days, he told me that the rust will come back near the handle and if it does he will argue the matter with Audi. The bodyshop had to foot the bill for the third repair because Audi said that they failed to repair it the first time but to be fair to the bodyshop (got to be nice to them due to them being my biggest customer) it does need a door on it. Audi obviously would go for the re paint option first but it clearly isn't the right option, chap at the bodyshop took photos of it when it had been shot blasted to show Audi if it comes back, he said that you can see the defect in the metal. I manage 5 different car brands and I must say I'm not impressed at all with the bodywork on all Audi's compared to the 5 I look after.
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  22. N8
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    N8 Kowalski Details VCDS Map User

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    [May 26, 2010]
    Pics or it never happened :ninja:

    Funniest line ever that
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  23. PH1L
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    PH1L Gievf Buckets VCDS Map User

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    [May 27, 2010]
    yeah i was fighting a battle with rust on one of my handles in the end i bought a new part and had it sprayed
    #22
  24. Gti Jazz Blue
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    Gti Jazz Blue Active Member VCDS Map User

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    [May 27, 2010]
    I have just picked my A3 up from the Audi approved body shop with a new replacement drivers door due to this rust issue.

    I contacted Audi Customer services and argued my case, in a polite way until they agreed to change the door.

    So now both of my doors are of the new design that allows moisture to drain from behind the plastic trim.

    Having had a loan Corsa 1.4 Automatic desire for 4 days it was great to drive the A3 back.

    Just need to apply sound deadner to the door inner skin and re-install my Focal Mid driver.

    Paul
    #23
  25. Garf
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    Garf Member

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    [May 30, 2010]
    My Dec 03 A3 has 3 or 4 spots of rust on the body, in various places, a few on the roof and on the bonnet. I think ill take mine to Audi this week and see what they have to say.
    #24
  26. SteveTDCi
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    SteveTDCi Active Member

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    [May 30, 2010]
    ok not an A3 but it appears out TT has a simlar issue so i'll be off to the stealer very shortly too
    #25
  27. AWong_A3
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    AWong_A3 New Member

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    [Mar 17, 2012]
    The Audi A3 does have a rust issue. At the bottom exterior of every door you will find a plastic strip that is screwed on to the door. Over the years of ownership and day-to-day usage, it is possible that the screws cause a rust spot to break out and eventually seep upwards towards the visible area of your car's door. I have a 2006 Audi A3 Sportback that is:

    1) meticulously maintained,
    - washed reasonably often at every 2 - 3 weeks,
    - parked indoors 90% of the time,
    - oil sprayed every 12 - 18 months,
    2) 100% accident- and/or bodywork- free
    3) 100% original paint from Audi factory in Germany

    and despite all that, all 4 of my doors are showing rust spots at said spot. I have gone to my local Audi dealer, Audi Midtown in Toronto, Canada, and the Service Department Manager Tony has worked with me to file a claim to replace all 4 doors under the Audi 12-year Rust Perforation Warranty. The reason for the claim is since this was:

    1) an issue that will 100% lead to perforation of my prized-possession's doors within the next 6 years
    2) repainting, according to Tony, will only be masking the rust which will come back

    I cannot get myself to let go of my beautiful car yet. I had a 2000 Toyota Camry that had bodywork done due to a previous accident, and the areas which had bodywork were a rusty mess after a couple of years, whereas the non-touched areas were extremely clean. This led me to conclude that as long as I drive safe and be kind to my car, that it will reward me by looking good for at least 12 years. Hence my choice to purchase a car that may have been a bit more expensive to buy and maintain than a Toyota or a Honda, but was an absolute joy to look at, drive in, and ride in - characteristics that a not a Toyota nor Honda could ever exhibit.

    Alas, now I might have to prematurely replace this car because if Audi Canada, for some reason, decides that I don't deserve the warranty coverage, then I would have to either:

    1) let the car rot and basically put an expected death date on my car
    2) repaint the car doors every year, which is extremely expensive and non-sensible considering Audis, when maintained as well as I have, should not visibly rust for at least 12 years. It has only been 6 years so parting with my car due to rust, that was not supposed to arrive until 12 years, is tragic.
    3) replace the car doors now or later, which will probably cost around 5 - 6 thousand Canadian dollars. Still very expensive and non-sensible considering Audis as mentioned above when maintained as well as I have, should not visibly rust for at least 12 years.

    Tony mentioned that it will take around 2 weeks for Audi Canada to respond with an acceptance of the claim, or rejection. Wish me luck. I will let you guys know what happens in 2 weeks.
    #26
  28. FranA3
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    FranA3 events moderator Regional Rep

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    [Mar 17, 2012]
    I've found a little bit on the bottom of my passenger door I'm just thinking shall i go and do a claim under the corrosion warranty
    #27
  29. AWong_A3
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    AWong_A3 New Member

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    [Mar 25, 2012]
    An update to my situation. Audi of Canada has approved replacing all 4 of my doors. Bringing the car into Audi Midtown on Tuesday, then they will apparently need 4 - 5 days to work on it. I'm hoping they really are replacing them and not just paint them over. If I'm promised 4 new doors, then I expect 4 new doors. I will update you guys again after I get the car back.

    Audi of Canada definitely rocked it this time! :rockwoot:
    #28
  30. AWong_A3
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    AWong_A3 New Member

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    [Mar 25, 2012]
    FranA3, your A3 looks mint, buddy! If
    your doors have never been replaced/repainted, I would give the 12 year rust warranty a try with your local Audi dealership. Just make sure you let them know right off the bat that the rusting is not something you could have prevented nor something you caused through neglect. It IS an unfortunate design issue. I'd be sad if my car looked like yours and the warranty claim got rejected. Good luck mate!

    #29

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