Rust?
 

I just got a 2004 RX-8 in May with 30,000 miles. Car looks nearly new, but last month while washing it well, I found rust. I was cleaning the door sills and found a rust spot on each side where the two doors meet. Anyone else seen this? I am going to take it to the dealer when I get a day off, but I don't know if that will fall under corrosion warranty, it is still kinda on the surface.

Cindy, do you know the geographical history of the car? Did it come from a location where road salt is used in winter? Your car is at the right age where salt corrosion shows-up as obvious. It starts in the nooks and crannies that typically don't get washed and waxed, or that a good washing just can't reach.

Be sure to post the dealer's reaction after they've seen it. Mazda dealer, I hope?

Car is from the first batch sold in Washington. Original owner was in the service. Took the car with him to Germany. He then got posted to Ft. Knox in Kentucky and traded it for a truck when he got back. So it has a pretty varied geographical history. 3 ocean travelling trips could provide part of the reason it is already showing rust.

yeah ocean=salt water=rust

Some rust off stuff should do the trick :) not that hard to fix.

Agreed, surface rust isn't a problem, it's the unseen rust on the inside of panels and welded seams. Chances are if there is visible surface rust though, it's much worse in the hidden areas.

jeez, I cant WAIT for rust..... Im just gonna keep on waxin.

The door sill rust spot issue is pretty common. The suicide door moves a little when the car is in motion, eventually rubs off the clearcoat at a certain spot on the door sill. I got the dealership to remove the rust spot and applied a 3M clear film to prevent future problem.

The bigger rust problem to watch out for is on the rear wheel fender lips.

Thanks for the suggestion. I showed it to the dealer this week, and they pointed out my perforation warranty expired 8/14/08, but told me they would have the Mazda rep look at it. I am going to call Mazda myself as well. In any case, I agree it has to do with the door. I would say that the 3m idea sounds like something to do.