Driver's Door sounds hollow

[Curmugeon]

We recently had some body work done at the local Toyota shop.
The driver's door, while not fully replaced, had the outer panel replaced and painted.
This from a small collision with a fencepost, paid for by our insurance company.

The door now sounds tinny. When you close it, it sounds like a 50 gallon drum had been
whacked and vibrates. The other doors on the Prius sound solid and don't vibrate when
you tap them.

We are taking the car back to the dealer tomorrow but what on earth didn't they do,
first time around? I am not inclined to rip into it myself to see what it looks like
compared say to our other Prius. Yes, we own two:-)

Thanks for any ideas. The shop manager seemed annoyed then cooled off to say they
need 4 hours to see what could possibly be wrong.

[N3FOL]

I can say right awat that it was not done right. After the repair, it should sound the same or better than the other doors. Keep on pushing your issue and hopefully you can get it fixed the right way.

[Shawn Clark]

Originally Posted by Curmugeon

The shop manager seemed annoyed then cooled off to say they
need 4 hours to see what could possibly be wrong.

He's got a lot of balls being "annoyed" considering he signed off on substandard work. This is one of those instances where he would be best advised to ask to have it demonstrated, then rapidly shift to the apologetic tone: "Something is not right, sorry about that, let us take a look at it so that we can figure out why this is happening and correct it for you."

Look, I've had good body shops screw up some facet of repairs and then do rework. 95+% of the job was done beautifully, but something was amiss like a mis-aligned bumper, or in one case the AC system was popping a relief valve. They didn't cop an attitude though. Instead we worked together to figure out why something didn't look/sound right so that they could determine how to make it right. In the end, these rework experiences have left me with a positive impression because the shops were eager to make it right.

You are more familiar with the vehicle than they are and are more likely to notice if something isn't right. Since you have two, there is no effective way for them to bluff you with the "they all sound like that."

[Rokeby]

Curmugeon,

IIRC, I have seen pictures showing some smallish pieces of sound deadening
material attached to the outside door panel. Use the search function to check
threads about "sound deadening" or "Dyna Mat" (There may not be a space in
D M) Some of the threads have before/after pictures and you will be able to
tell if there is in fact OEM material. This would be an iron clad arguing point if
you found it missing on the repair. (These threads also show how to remove
the inner door panel, window switch, etc.)

Tangentially, FWIW, from day-one, I thought the rear doors sounded tinny
when I closed them. An unanticipated result of mounting the after-market side
moldings is that at least to my ear, the doors now sound less tinny, more
substantial. (Mouldings are available from the PriusChat Store, and very easy
to install. Again, use the search function to check for threads on side molding.)

[dogfriend]

In the Body Repair manual, there is a note to apply body sealer between the internal door structure and the outer door skin. Perhaps the body shop did not follow this procedure.

[Curmugeon]

Thanks folks. Saw some pictures, have the pdf. Simply tapping the door panel, is like strumming a musical instrument. I don't think there will be any doubt about it not being correct. For what it is worth, and unrelated, rather than removing the left front plastic wheel insert they cut a hole to access the screw to remove the front left fender. I guess that was easier than removing the whole thing but the least they could have done is patch the hole (about 2 " long and 1" wide) don't you think? This is a Toyota shop. Looks like a great forum. With 2 Priuses, 2005 and 2006, looks like this will be the place to get some early ideas on what's next!

[dogfriend]

Originally Posted by Curmugeon

, rather than removing the left front plastic wheel insert they cut a hole to access the screw to remove the front left fender.

I wouldn't be happy about this either. It seems like this would be a way for mud and water to gain access to areas where it isn't supposed to be. There might be an increased risk of corrosion behind the plastic liner as a result. They should repair this.

[Curmugeon]

The body shop manager had no problem with the noisy door. Kept it around an hour and
apparently glued something internally with polyurethane. Problem fixed. Said as the stuff dries,
it would be even better.
The hole in the liner perplexed him. 'No one here would do that. It's easier to just take the liner out".
My reply "Ahhhh, I didn't do it and there's been no one else working in this area".
He quickly acquiesced and said they'll order a new one. In, in a couple days.

He theorized a technician who is no longer employed there is the likely villain
in both instances;-)

Now to research fuel quantity indication problems...

[dogfriend]

Originally Posted by Curmugeon

Now to research fuel quantity indication problems...

Try a search using the phrase "guess gauge".

[Jay in Clovis]

Sounds like they forgot the sound deadner, It's a material applied to the inside of the door skin to help with road noise.
Then car does have a considerable amount of road noise but is not a problem with me.
I just got a 08 and the door sounds a little "tinny". I checked all the other ones they had on the lot and they all sounded the same.