I just noticed today that I have rust on the top of the folded seam on the inside of the front passenger door. The other doors appear to be OK.

 

It should be an easy enough repair Black Rose. My GM dealers body shop sealed it up with some sort of gunk and sprayed it with some paint. It looks pretty good and it seems to be doing the job because I've yet to see any corrosion since the repair.

 

This is more common than you think, ive seen it on a few cars only a couple years old. Oddly, it seems to be ones that are washed freqently. My theory is that moisture and dirt are trapped in the seams and accelerate the rust. If you wash that area I recommend blowing it out with compressed air or something similar.

 

I have the same issue on a car that is not quite 2 and a half years old. The dealership refuesed to do anything about it. Mine actually looks worse than the picture posted.

 

I have the same issue on my HHR, but it affects all 4 doors. Mine will be getting fixed sometime in August.

 

Just took my car in for this rust problem my, it had actually started eating into the metal on mine, on the driver side. The pass side has bubbles.

 

On my 2008 Panel there are three drain holes on the front doors and two on the back. No rust.

These holes will not allow the complete drainage of the door because they are a millimeter or so above the bottom. Water and eventually mud will accumulate there.

I suggest flushing out this area drying it thoroughly then trying to get some liquid in there to block the water to metal contact. Can anyone better informed suggest anything better than a coating of oil?

 

Try "Water Displacement - #40"
(aka WD-40)

 

My 06 HHR has the same rust problem on the driver door.

Is GM doing anything about this?

 

I just got mine back yesterday they had to grind down and repaint/seal the doors, driver side and passenger. I was talking to the mgr and he told me that it will always be covered under the 100,000 corrosion mile warranty, he said it does not have to be a hole all they way through. It has to be eating through the metal, it wont cover surface rust and bubbles. But they did a good job so lets get through some harsh winter roads covered in salt and see what happens.