Rust Prone Areas
Below are two pictures of areas most prone to rust for Minis
Headlamp surround and bowl (part of front wing). These rust out from behind due to accumulation of road dirt and moisture, usually only in locales where salt is used on ice.
Lower front valance. Often kerbed and hit by stones, and therefore prone to rust where paint is chipped away.
Lower windscreen surround, top of wing, top of a-panel. These areas rust because of the box section inside this area, which accumulates road dirt and water. The rear seam of the bonnet also rusts because of the foam soundproofing it sits in that retains water.
Lower edge of a-panel. Rusts out from the inside.
Roof skin edge/cant rail. A trap for dirt and rain, prone to rust from the outside in as paint wears. Rust is accelerated greatly on Mk1 cars with sound proofing foam inside the cant rail.
Rain channel (Mk1/2 cars). Does not drain properly, by design.
Door lower edge. Rusts due to blocked door drainage holes.
Inner wing/front of sill. Very prone to rust from accumulated road dirt.
Outer/inner sills. Very prone to rust from road dirt/water trapped inside, and paint chips.
Lower edge of body sides. More common where road salt is used.
Rear subframe. A common casualty of inadequate factory rustproofing. The heelboard is also likely to be rusted.
Roof skin/cant rail See 5.
Boot lid. Prone to rust along the bottom edge. The same applies to van/estate rear doors.
Rear panel/rear valance/rear bumper mounting flange and boot floor.
