get of your butt and post a picture of your problem Both Lenny and I have made the effort [for the benefit of others] That way anybody else wanting to confront Ford with this obvious design fault, has the evidence of other Foci with the same problem. Saves time them bullshitting the complainant that its a one off and not their [Fords] problem. Besides Lenny's picture was crap
Lenny I agree with you what the problem is, and like you have decided to fix it myself, for the reasons you gave in regard to possibly them just doing a cosmetic job. I've expanded the area until I hit virgin metal. As rust creeps under the paint finish, dependent when remedial action is taken dictates how big an area that is. In my case on a 5.5 year old car it means the rust creep would be more than yours or Daryll's.
Now I treated and applied finish coats a couple of weeks back. And at the time I decided like [yourself] to remove the cause of the problem all be it in a different way. I cut a rectangle of what can best be described as a rubber compound. It was an off cut to a garage door leaf/draft excluder I had fitted a couple of years back. I very rarely throw anything away that at the time I think "that might just come in handy" And the wife has the nerve to call such stuff junk..........women what are they like.......if they cannot smear it on their skin or wear it...its rubbish
Anyway I've been letting the repaired area harden before super gluing it to the bulkhead, just in case of a possibility of there being a chemical reaction that broke down the paint finish if it was not fully cured. So no picture fitted but here it is
Edit: As it looks massive in the photo, I'll add the rubber patch measurements. They are 35mmm x 20mm, which is way bigger then what I exposed length wise. I'm going to glue it on the short edges and the top edge, on old hardened paintwork. Leaving the bottom unglued in case water does some how creep in from the top. I'm expecting the top and side seals to be water proof, but you never know.
Oh the rubber pad is 2.30mm thick......I measured it with my digital tyre tread depth gauge