i've found a bit in my driver side door, have yet to even check the other doors. i'm not taking it back to teh dealer i baught it from, they can kiss my white baby skinned @$$.

alot of this is caused by flexing of the chassis while driving. another reason why having a fitted roll cage installed in the xB should be done so that it take away ALOT of this problem.

 

This has nothing to do with flexing. Even if ithe car is flexing, the door is only attached to the chassis via the hinges and the latch. Rest of the contact is around the rubber seal around the door opening. The door itself doesn't really flex all that much. Especially the rusting part around the windows.

The rust discussed in this thread is caused by incomplete application of paint in the areas where the extruded metal parts of the door are welded together. Water intrudes into those areas and rust forms. This would happen even if you took the door out of the car and jut let it sit outside (unflexed).

 

No rust seen Yet. All Good.

 

I found rust in the corner of my driver door to LOL i even seen it at night LOL!!! Has anyone token it to the dealer and and if did what did they say??

 

What's weird is my rust went away - like maybe it was some iron dust that was on the paint or something - there was never any more on it after finding it on several of my doors that first year. I still want to get under the carpet in the back and see what's going on under there.

 

interesting to see this... especially the dates. I have an 04' and still no rust.

 

I have a little on my driver side door too...

 

check the back doors under the rubber gasget above the window post, there is a small phillips head screw,both my back doors screws are rusted out!

 

I found a little tiny spot of rust on the back of my hatch. Hasn't gotten any bigger though...Boo to rust.

 

you sure it isn't brake dust stuck on the paint?

 

I haven't found anything but then again i have only had it for a month. Im going to give it the once over this weekend when i give it a bath. hope i find nothing.

 

Back when this first came up I thought there might be a problem 'cause the paint in that area of mine looked rather thin, so I've kept an eye on it. Six years now and zero rust.

I don't think mine has a problem.