VW California - T6.1 ONLY - Roof corrosion General Discussion.

[MisterTea]

So. The T5 had roof corrosion.
Seems the T6 has the same issue.

Any insight into any changes they should have applied to the way the T6.1 has been built that would/should stop the issue appearing on the 6.1?

Anyone taken a close look at this yet?


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[WelshGas]

There will be no change to the roof system.

 

[Loz]

Although it may have tape applied at build. we await the first verdict.

 

[MisterTea]

There will be no change to the roof system.

Yep. That’s what I’m worried about. But on the basis the T6 issues were not as bad as the T5 issues (if I’ve understood it correctly, the issue with the bulge above the driver cab area was resolved in the T6?)

So I’m hopeful that the raising roof edge has been factory fitted with the tape.

And then it’ll just be a matter of time. To see if that’s It......

But I don’t presume so.


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[WelshGas]

Yep. That’s what I’m worried about. But on the basis the T6 issues were not as bad as the T5 issues (if I’ve understood it correctly, the issue with the bulge above the driver cab area was resolved in the T6?)

So I’m hopeful that the raising roof edge has been factory fitted with the tape.

And then it’ll just be a matter of time. To see if that’s It......

But I don’t presume so.


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The problem with the section above the windscreen was resolved in MY 2015, so vehicles built mid 2014 onwards, apparently.

 

[clarinetbcn]

Perhaps a different primer paint will be applied to the roof perimeter, as was done to mine during the repair. I don't know how that could be known, as VW are extremely reluctant to discuss this even with owners who have had the repair done. I had to push far harder that I think was reasonable before I got a detailed description of the work done one year ago.

 

[WelshGas]

Perhaps a different primer paint will be applied to the roof perimeter, as was done to mine during the repair. I don't know how that could be known, as VW are extremely reluctant to discuss this even with owners who have had the repair done. I had to push far harder that I think was reasonable before I got a detailed description of the work done one year ago.

All they have to do is change the rubber seal around the edge for one without a metal insert. Problem solved.

 

[clarinetbcn]

The metal insert is a necessary design element to give the seal the form and rigidity it needs to do it's job, as explained to me by a friend who is a Seat design engineer here in Barcelona. The problem is that it's made of steel. But, if we can put a man on the moon, etc., etc........

 

[SusiBus]

The metal insert is a necessary design element to give the seal the form and rigidity it needs to do it's job, as explained to me by a friend who is a Seat design engineer here in Barcelona. The problem is that it's made of steel. But, if we can put a man on the moon, etc., etc........

When this was being discussed on the forum back in 2014 a member posted that be had identify an American manufacturer who made seals with plastic inserts instead of steel.
Also considering the cost of repairs, would stainless steel not be an option, it would surely be worth the extra cost if only to finally put an end to the roof corrosion saga, and help restoreduce some faith in the brand

 

[Keith Smith]

I'm not convinced that the metal insert is entirely to blame and would solve the problem of they changed it. On my 3 year old Cali the insert had rusted badly at one corner but the paint was still intact. Whereas the front edge had paint bubbling along its entire length with no sign that the insert had protruded out from the rubber. Plus I could just peal the paint off in places well beyond the edges of the seal. It's unbelievable to me that a company with the resources of VW can't solve this problem and leaves me to believe they don't care.

 

[ArunAlec]

I recently did a Google to look for information regarding aluminium corrosion related to car bodies. One of the experts said that any workshop carrying out work on steel and aluminium body panels should have a dedicated set of tools for work on aluminium which should not be used on steel to minimise the risk of cross contamination of any steel particles onto the aluminium.
I wonder how many non specialist workshops are that meticulous!

 

[Jay20cali]

All they have to do is change the rubber seal around the edge for one without a metal insert. Problem solved.

Couldn’t agree more!!!

 

[Jay20cali]

I'm not convinced that the metal insert is entirely to blame and would solve the problem of they changed it. On my 3 year old Cali the insert had rusted badly at one corner but the paint was still intact. Whereas the front edge had paint bubbling along its entire length with no sign that the insert had protruded out from the rubber. Plus I could just peal the paint off in places well beyond the edges of the seal. It's unbelievable to me that a company with the resources of VW can't solve this problem and leaves me to believe they don't care.

Landrover defenders have suffered this for there complete existence.i deal with this issue on every landrover I ever restore the dissimilar metals are the big problem ie metal alloy st/steel all reacts against each other causing galvanic corrosion...but also a problem is how there etched and painted if the etch isn’t applied well it will lift after time

 

[clarinetbcn]

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Landrover defenders have suffered this for there complete existence.i deal with this issue on every landrover I ever restore the dissimilar metals are the big problem ie metal alloy st/steel all reacts against each other causing galvanic corrosion...but also a problem is how there etched and painted if the etch isn’t applied well it will lift after time

That’s why we’re hoping the new primer paint will help, but it’s not a long term solution, as all LR owners know. Once again, if we can send a man to the moon..., but this issue does not appear to be a priority for VW R+D.

 

[Borris]

The metal insert is a necessary design element to give the seal the form and rigidity it needs to do it's job, as explained to me by a friend who is a Seat design engineer here in Barcelona. The problem is that it's made of steel. But, if we can put a man on the moon, etc., etc........

I believe that the metal insert is there purely to provide the necessary grip to keep the rubber seal from falling off. The automotive industriy having been using this system for donkey's years. They always rust in the end in any areas that retain moisture such as joints. When it gets really bad the seal just doesn't stay put any longer. They probably use this type of seal because they always have and it's easy to remove and replace when carrying out repairs and maintenance. However, I believe that unlike most other applications this type of seal is unsuitable for a California roof seal as it basically forms a gutter that will always hold moisture. Moisture eventually leads to rust and then, unless a suitable barrier is in place, to bi-metalic corrosion in the adjacent aluminium roof structure.

So why not produce a seal that can be bonded onto the roof edge. They bond windscreens in place so why not roof seals? If it ever needs to be removed then there has to be ways to do that. How often would a bonded seal fitted to a California roof need to be removed? I suggest almost never. No steel need be involved. If it needs rigidity, which somehow I doubt, then there are other materials that could be imbedded in the rubber seal that wouldn't cause problems. Afterall the seal has to perform two functions,
1. To stay attached to the roof. Hence the steel internal gripper.
2. To form a seal between roof and bodywork. The steel element plays no part in this function.

If bonded there would be no gutter effect, no water retention, no rust and no roof corrosion.

 

[Keith Smith]

Alternatively why not fit the seal to the body and have the roof close onto it?

 

[ArunAlec]

Alternatively why not fit the seal to the body and have the roof close onto it?

Agree, it would mean the seal would not need any metal in it and could, with a bit of thought simply be bonded to the fixed part of the roof.

 

[Loz]

Alternatively why not fit the seal to the body and have the roof close onto it?

It would be worse as the paint edge is poor on the roof and the paint stops sharply on the edge.
The best fix would be a carbon-fiber roof.

 

[billlynotts]

I thought VW had resolved their issue by reducing the paint corrosion Warrenty from 12yrs down to 5yrs on Cali’s

 

[Keith Smith]

It would be worse as the paint edge is poor on the roof and the paint stops sharply on the edge.
The best fix would be a carbon-fiber roof.

Car doors seem to manage having a painted edge, but I agree the paint is poor and I think they could solve the problem with a better paint system.

 

[Loz]

Car doors seem to manage having a painted edge, but I agree the paint is poor and I think they could solve the problem with a better paint system.

Car doors normally have rolled edge so a bit thicker on the edge and more rounded. When i had the seal off mine it is very square and they dont pait underneath as its grey on the underside.
They should really do an acid etch primer and then paint them properly top and bottom.
I discussed this with a friend of mine who owns the company that provides most of the blue motorway signs, these are all aluminium and have to have a 40 year paint guarantee. The method is to use an acid etch primer and this seems to be a much better way of doing it.

 

[Keith Smith]

It's hard to understand why they haven't fixed this after all these years, but then we keep buying them? It's hurting them in other ways though as we were going to get a Tiguan last spring but VW and the dealers were appalling and in the end we bought an E-Pace. Jaguar have a reputation for poor reliability but so far it's one of the best cars we have ever owned. Knocks spots of the VW.

 

[Louis II]

I'm about to follow up with my local dealer on a date for the roof corrosion repair on my T5.1.
I would be interested to know if anyone with a T6.1 been brave enough to take a look at the roof seal to see if the factory fix is still to apply the clear tape and glue the seal in place?

 

[Saesneg Shaun]

Opinions on this please guys, Looks to me that the seal is rusting/explanding?
Is this a problem similar to the earlier models?

 

[ArunAlec]

Opinions on this please guys, Looks to me that the seal is rusting/explanding?
Is this a problem similar to the earlier models?

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My guess is that it’s not the roof corrosion but rusted inner of the black sealing strip/rubber. That’s not say that the rusty steel hasn’t damaged the paint and allowed corrosion to start.
Have you had the VW “recall” to check that the roof has a tape fitted between the paint and seal?