Having one of the earliest cars (built July 2002) I guess mine will run into problems that others will have later on.

I've also read that early cars had quality control issues - and I recognise that, with some clear issues in the paintwork on my car.

Rust has started now in the obvious places, at the bottom of the rear wheel arch where the arch connects to the chassis at the front of the arch and also at the back of the arch where the body and rear bumper meet.

I think I'm going to use some rust convertor on the front end of the arch and then coat over with underseal.

Anyone else got any corrosion yet?

I have a few small spots on my '04 Fusion 2, but I've just been sealing them with nail varnish..

does nail varnish really work???

Well the patches of the stuff I've painted on so far are yet to wear/flake/come off, so I guess that the barrier it provides against water and salt can only be a good thing. It also helps to 'stick down' the surrounding paint to stop it also flaking off when the metal underneath starts to disintegrate.

One thing is that if the rust is particularly prevalent, just painting the varnish on on the outside of the car won't stop any rust spreading on the other side of the metal, where you won't necessarily be able to see.

The spots on my car, when I say small, are smaller than the diameter of a pen at their biggest, or are lines eg. where a metal part overlaps another.