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Are the Prius prone to rust at the lower front edge of the front doors?

Discussion in 'Prime Care, Maintenance and Troubleshooting' started by sylvaing, Jul 19, 2023.

  1. sylvaing

    sylvaing Senior Member

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    Both front doors on my 2017 are showing rust at their lower front edges. On the driver door, it even started to show from the outside. Is this common for the Prius to rust there? I took out the rubber grommet nearest to the edge, blasted some air and then applied Fluid Film in and out, hoping to slow down its progression.

    I wanted to clean it better from within the door through the speaker opening but that speaker is riveted in place! What? Why do that! Anyway, that's the best way I found. Any tips to slowdown its progression even further?

    Thanks
     

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    #1 sylvaing, Jul 19, 2023
    Last edited: Jul 20, 2023
    bisco likes this.
  2. bisco

    bisco cookie crumbler

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    from my experience, no. especially after 6 years
     
    #2 bisco, Jul 20, 2023
  3. sylvaing

    sylvaing Senior Member

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    no to what? Prone to rust there or ways to slow down progression?
     
    #3 sylvaing, Jul 20, 2023
  4. bisco

    bisco cookie crumbler

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    they are not prone to rust at those locations in my experience, and i haven't seen many complaints here.
     
    #4 bisco, Jul 20, 2023
  5. sylvaing

    sylvaing Senior Member

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    Ok, thanks.
     
    #5 sylvaing, Jul 20, 2023
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  6. Rog17

    Rog17 New Member

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    Looks exactly like my white 2017 front doors. Any easy repair ideas?
     
    #6 Rog17, Aug 20, 2024 at 10:07 PM
  7. sylvaing

    sylvaing Senior Member

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    Last year, I applied OSPHO on the inside of the door (riveted out the speaker to have access), removed the original caulking, cleaned it up, repainted it (only had a paint pen then) and applied a new caulking bead. The passenger side which only started rusting from the inside hasn't continued and looks rust free but the driver door is becoming worse. Rust is starting to burst on the outside :( I've bought Bondo, Blue Magnetism spray paint, cleat coat spray and clear coat blending spray. My idea is to remove all the rust, use OSPHO, Bondo the repair, sand, repaint the area, clear coat it and use the clear coat blending to 'blend' the new clear coat with the old. Waiting for the temperature to be milder. Because of the location, I might have to remove the door (or the fender, depending what's the easiest) so I don't damage the fender while working on it. Another reason why I'm putting it off lol.
     
    #7 sylvaing, Aug 21, 2024 at 6:38 PM
  8. Mendel Leisk

    Mendel Leisk Senior Member

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    Whereabouts in Canada?
     
    #8 Mendel Leisk, Aug 22, 2024 at 6:09 AM
  9. Leadfoot J. McCoalroller

    Leadfoot J. McCoalroller Senior Member

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    Because it's a low-cost way to guarantee a rattle-free installation. It's not that big of a deal to drill out the rivets, nor is replacing them with fresh pop-rivets afterwards.
     
    #9 Leadfoot J. McCoalroller, Aug 22, 2024 at 8:46 AM
  10. sylvaing

    sylvaing Senior Member

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    Asking me or Rog17?
     
    #10 sylvaing, Aug 22, 2024 at 8:33 PM
  11. Mendel Leisk

    Mendel Leisk Senior Member

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    Sorry, yes, you. Presumably lots of salt?
     
    #11 Mendel Leisk, Aug 23, 2024 at 6:15 AM
  12. sylvaing

    sylvaing Senior Member

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    Yeah, in the Ottawa region, lots of salt. However, whenever I see a Gen4 parked Prius or Prime, I look down to see if there's any rust starting there and I haven't seen any. I'm thinking it's a manufacturing defect but with the rust warranty being so short on those cars, it's long gone so I have no recourse with Toyota.
     
    #12 sylvaing, Aug 23, 2024 at 9:34 AM
  13. Starship_Enterprius

    Starship_Enterprius Active Member

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    My 2010 also had the same problem, but only on the passenger side (i'm in Ottawa too). I just cleaned/claybar'd that portion and kept it at bay until the last year when the engine seized and i junked it. Yeah it also had the oil burning problem too, and the seizing brake calipers problem. Worse prius gen in my opinion but it lasted 14 years so hopefully that indicates my Prime with no detectable problems will last longer lol.
     
    #13 Starship_Enterprius, Aug 23, 2024 at 9:42 AM
  14. Mendel Leisk

    Mendel Leisk Senior Member

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    I recall there's been several (Priuschat) threads regarding door drains. Maybe 5th gen in particular of late. Here's one I found for fourth gen:

    Door drain holes | PriusChat

    My guess would be there's some pocket/convolution inside the door, which is proving difficult to drain properly.

    A solution to stuff like this is to ship prototype cars of each gen, early on, to the countries they sell in, driving them extensively, If there's salt belt regions for sure test some there. Then check them over, thoroughly..

    Seems to me Toyota is not doing this, or not doing enough. And/or not piling enough miles, say for typical North American driving conditions. Probably because their competitors aren't doing it either, it costs, and so on. Seems like they're not even doing this in Japan, considering the debacles that arise with pretty much every generation
     
    #14 Mendel Leisk, Aug 23, 2024 at 10:33 AM
  15. sylvaing

    sylvaing Senior Member

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    Yeah, whenever I clean the bottom of the doors, I always have to reposition these flaps as they get crooked. I wonder if that could be the reason. The previous owner never repositioned them, defeating their use and water accumulated inside...
     
    #15 sylvaing, Aug 23, 2024 at 10:40 AM
  16. Mendel Leisk

    Mendel Leisk Senior Member

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    Periodically running a zip tie up and around in all these seems a good idea, say after every carwash. Our parade of Hondas over the years, I think one of the manuals mentioned checking those. I've forgotten about that of late. :unsure:

    I appreciate that doesn't address your current issue. Bite the bullet and have a body shop assess it? I'm not really sure there is long lasting solution, at least one that doesn't break the bank. I think you'd want to pull the inner panel off, and the vapour barrier, see how accesible it from the inside. For starters. Still, that rust is way in the corner, beyond the panel opening. Boroscope might help, with that inner panel off.
     
    #16 Mendel Leisk, Aug 23, 2024 at 12:05 PM
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