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Old 08-05-2015, 02:34 PM   #1 (permalink)
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Location: 1000 Islands, Ontario, Canada
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Blackfly - '98 Geo Metro
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Last 3: 70.09 mpg (US)

MPGiata - '90 Mazda Miata
90 day: 53.56 mpg (US)

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90 day: 61.98 mpg (US)

Fancy Metro - '14 Mitsubishi Mirage top spec
90 day: 58.72 mpg (US)

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2004 Toyota Prius body rust / corrosion (rocker panels, front fenders)

NOTE: I split this discussion from my Prius build/ecomodding thread because it's something specific that other owners will be searching for more and more as these cars age.


My 2004 Prius is rusting out in several places.

It's worst in the rocker panels, but the front fenders have also started to go. This thread will show where and hopefully why the corrosion has started,so owners of newer cars (or older cars in less rust-prone parts of the world) can take steps to prevent it.

Eastern Ontario & west Quebec are perfect laboratories for discovering automotive design flaws that cause rust by trapping moisture, winter road salt (the killer) and dirt.

Here's what the rocker panels look like when I got the car

It was easy to poke that screwdriver through the side of the car.

I have an idea about the cause/path of this rust, and hope to offer some good preventive info to owners of newer cars (or cars that live in less salty winter environments) that haven't begun to rust... yet.

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Latest mods: 3-cylinder Mitsubishi Mirage. EcoMods now in progress...
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Manual vs. automatic transmission MPG showdown

has launched a forum for the efficient new Mitsubishi Mirage - fuel efficiency info for Geo Metro owners - electric car conversion on a beer budget
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