Paint fault!

[wolfie]

I bought my little Polo 1.2TSi SEL back in May 2011 and it's been a great little car, quiet, economical, goes well enough. I've had no mechanical issues with it what so ever, not even had any trim rattles. Generally it's been a cracking little car.
That was up until about 6 weeks back. While cleaning the car I happened to notice that there was some "spider corroision" (that what the paint chap called it) that was emerging from behind the mastic seal at the front edge of the passenger door.

I've added an image below. (Door edge)



Car was booked in with VW warranty to assess the fault. Following day they got back to me and car was booked into the body-shop for repair. Initially they body shop wanted to have the door replaced but VW warranty would only action the repair. Now I had a chat with the chap in the paint-shop and he said in his opinion the repair would be absolutely fine . But if they see corrosion of any sort they normally request a new part as a matter of course.
Wind forwards 3 weeks and car is back from the paint shop, standard of repair was excellent and the comment from the paint-shop was it should be fine but keep an eye open in case it comes back or any more emerges.

Jump forwards to this weekend and while cleaning the car I popped the bonnet and noticed I have another area that is starting to corrode from beneath the seam on the drivers side edge of the bonnet.



So back off to VW again this morning for another paint fault claim!! So far they have been very good, but that doesn't stop me being completely hacked off with a car that is so new should have zero corrosion isssues. Worse than that, this is the second area that it has appeared on the car in the space of a couple of months. So much for VW's quality control.

I've posted up just to make folk aware and perhaps have a little check round their own mastics seals. Just in case...

If we do have any professional paint guys on the forum I'd be interested in your opinion. Do you recon this would be an isolated thing, or is the car likely to full of corrosion in a couple of years. (this is my gut feeling) Car has never been in any accident or had any repair at all. For 3 year old car it's close to mint.

Car is a 5dr, in Reflex Silver.



Cheers

[zebraman]

It's not something that should be happening on a three year old car, that's for sure.

However it will be a long time before this turns into a structural issue. It will be interesting to see if any other owners have this issue with similar age cars.

[wolfie]

It's not something that should be happening on a three year old car, that's for sure.

However it will be a long time before this turns into a structural issue. It will be interesting to see if any other owners have this issue with similar age cars.

It's definitely not something I'd expect to see on any modern vehicle. I've owned Vdubs since the late 80's and I've never had any paint issues what so ever. I had my previous Polo for over 10 years and the paint was better on that at 10 than it is on this one at just 3 Though it may be years away from being structural, I'd be highly surprised if anyone who saw a paint defect like this and not have some concerns. Plus this is what can be seen on the outside, what could be going on where it's not as accessible?

The reason I've posted was just to put it out there and see if there are any others who may be having similar issues and as yet have not noticed. I only picked it up by chance because I was giving the car a thorough detail/clean.

My two main worries are will Vdub continue to fix it for free in the long term should it continue to deteriorate and how widespread is the problem on the car. So far it's appeared at two different locations (bonnet & door) on the car, Who's to say that in 1,2,3 years+ it doesn't become apparent on all the seams? Cosmetically the exterior of the car is perfect and unblemished.

Another reason for posting is I was hoping to possibly have someone who is a professional repairer to suggest what may be the cause.

I'm gutted at the moment, this car was going to be my "keeper" in every other respect I like the car. Sods law I have some on going health problems and income just wont stretch to trading it on for something else. So I'm stuck with it, unless I just sell it and buy something cheaper. (but I don't like the idea of passing on problems, call me old fashioned)

[nry]

Unless you find it on the main chassis, having it limited to the removable panels means VW can replace those and it should be sorted out, though I'd be checking the entire car over myself just to be sure. Seems strange this has affected the bonnet and door, not even sure what that suggests as to the cause.

[Steve9413]

This might be a pointless point but i know on some VAG cars there is a TPI (Technical Product Information) on the sound insulation on the bonnet to be replaced due to it being mouldy? so i don't know if the moisture could contribute towards this spider rust.

[wolfie]

This might be a pointless point but i know on some VAG cars there is a TPI (Technical Product Information) on the sound insulation on the bonnet to be replaced due to it being mouldy? so i don't know if the moisture could contribute towards this spider rust.

Insulation material beneath the bonnet is still in perfect condition and is not within a couple of inches of the problem area anyway. Cheers for the thought though.

It just happens I was talking to a neighbour about it last evening and I didn't realise that he had worked in a body-shop some years ago. He thinks it's definitely a manufacturing problem. Modern vehicles are dipped in various nasty chemicals to clean and de-grease them prior to protective and finishing coats being applied. If these are not rinsed effectively and dried fully before the seams are sealed the sealants effectively trap the soluble salts within the seams. Over time theses salts begin to react with the various substrates of metal/paint/etc. It's not moisture getting in, so much as a chemical reaction from contaminants. It may be localised to areas when it not been rinsed effectively, but as you can see once the reaction starts it spreads anyway.

Warranty are due to get back to me over the next couple of days to approve the work. I'll have a word and see what they say.

[vc-10]

I'm assuming this would be covered for the full 12 years of the VW anti-corrosion warranty?

[sony]

Just checked mine and all is ok! Thank god. So yes, I'd assume you are one of the unlucky ones. Saying that it will be cover by the corrosion warranty anyway!

[wolfie]

I'm assuming this would be covered for the full 12 years of the VW anti-corrosion warranty?

You would have assumed so wouldn't you, but that's where "Smoke and mirrors" meets the small print and sales patter.

Body protection warranty

All current Volkswagen vehicles are fully protected during manufacture against through corrosion for 12 years from the date of first registration.

The only preconditions are:
•The defect must be reported to a member of the Volkswagen Authorised Network as soon as it is discovered and within the warranty period.
•The perforation must not have been caused originally by damage, neglect, insufficient care or maintenance or by external rusting.
•A member of the Volkswagen Authorised Network must be advised about any rusting as soon as it is found.
•All body repairs will be carried out promptly in accordance with the manufacturer's specification and procedures, using only approved parts and materials, so the original level of anti-corrosion protection is maintained.


Having spoken to the warranty Rep, and had the car assessed at the local dealership (who was very professional, helpful and approachable). What it covers is a perforation of the body from the inside-out. So unless it's actually a hole and you can prove it rusted through from the inside, which is nigh on impossible to do, it won't be honoured. I said that it basically means the 12 year anti-perforation warranty isn't really worth the paper it's written on, and she didn't disagree. Generally any and all paint defects outside the 3 year standard warranty are "A good will gesture" they may meet all or just a percentage of the repair cost. Over the years there have been a few cases where there has been a "known" manufacturing fault or defect that have been done on cars that are almost at the end of their corrosion warranty. But generally successful claims for perforating rust are non-existent.

Pretty hacked off at the moment, the Polo was intended to be my "Keeper" but I have very large reservations as to whether this will be an on-going paint problem.

[wolfie]

Just checked mine and all is ok! Thank god. So yes, I'd assume you are one of the unlucky ones. Saying that it will be cover by the corrosion warranty anyway!

Nice one, I wouldn't want anyone to be in the same situation. I wouldn't even know if there was a possible common factor. But would advise anyone who has a car of similar age just to have a quick look, just in case!

Mine is 2011(May), so just over 3 years old, a 5dr 1.2 TSi SEL in Reflex Silver. I've owned the car from new, it's had no knocks or bumps and is otherwise unmarked. I am not sure if they are built at the same location as the 3dr version (dunno if that has anything to do with it, just a passing thought)

[sony]

Mine is a white 2010 (60) Polo GTI- but crucially a 3 door. I'm pretty sure the 3 doors are built in Spain and the 5 doors in South Africa.

[wolfie]

Mine is a white 2010 (60) Polo GTI- but crucially a 3 door. I'm pretty sure the 3 doors are built in Spain and the 5 doors in South Africa.

Yeah that's what I thought, will have a proper look later. (not that it makes any difference, just interested)

[wolfie]

Tiny update. Warranty claim conformation has come through and I have a another repair slot booked in the paint shop for the 17th. I plan to have a word with the chap in the paint shop and see if I can get a candid opinion as to what may be the cause and the likelihood that it will continue to deteriorate in the future. (I doubt he will be very forthcoming but it's worth a try)

[nry]

Trading Standards are the people to speak to if you ever have issues, they helped out with my Astra a few times on bodywork issues and got things sorted for me that Vauxhall refused initially...or blatantly lied about (e.g. we only offer warranty repairs on the same issue twice, if it happens a 3rd time it's my fault

[wolfie]

Trading Standards are the people to speak to if you ever have issues, they helped out with my Astra a few times on bodywork issues and got things sorted for me that Vauxhall refused initially...or blatantly lied about (e.g. we only offer warranty repairs on the same issue twice, if it happens a 3rd time it's my fault

It's crossed my mind to get in contact with Trading standards. For the moment I've given VW customer care a ring to make them aware that I have on-going issues with the vehicle. To be honest I got the impression they didn't give a stuff. I asked them If they would like me to send some images of the paint fault and they were not interested. They simply said they'd log the fault on the "system"

Thing is paint issues aside I really like the car, which is why I'm being so patient. I was happy with the quality of the initial repair BUT at that time I thought it was an isolated fault and that would be the end of it. Now it's appeared again in an entirely different area of the vehicle my thinking is that something went wrong during the paint process and the problem is only going to get worse as time passes. It's in for the second repair next week and if the paint chap thinks it's possible that it will effect the whole car. I'll pitch in then and see what they suggest. So far the dealer has not been interested other than quoting me a trade price on the car. (Which was actually a lower price that I could get at the garage up the road)

I'm also of the opinion if it's appeared on mine, there's a fair chance it will manifest on other vehicles built around the same time. That's why I posted on here, just in case someone else either has the problem, or hasn't checked and has it unknowingly. Or we have some clued up paint peeps using the forum.