odd protrusion of the driver side door
 

Hello all,

I have an odd protrusion on the driver side door. It started about a month ago and has steadily got worse. The car is a 13 frs so well past warranty. Car has never been in an accident, nor can I find any evidence of a hit and run. The crease is stiff with no give to the sheet metal.

I took it to the dealer, they have no idea what it could be. They of course are happy to charge me to take it apart. Should I let them and hope they will cover it under warranty? (assuming its a manufacturers defect) Or should I just go to a body shop and pay out of pocket?

Anyone see anything like this before?


I live in Canada if this makes a difference.

Thanks all.

Hi Rust. Can you back the pics off a bit so we can tell what we are even looking at? They may make sense to you but I have no clue where it even is.

Sorry, site has me crop the pictures down. This is from a month ago. the line now runs about half the length of the door.

And wash the car, the other side have the same?

wow that looks pretty rough, certainly not normal. not sure how something like that could happen unless the bottom edge of the door was pressed up against something...

I did wash the car lol. The pictures from the car wash are too dark to see anything. Welcome to Alberta roads where everything gets dirty in 3kms.

Other side of the car is fine.

Not to my knowledge. The line is slowly increasing in size though; really baffled I am.

I feel your pain on the dirty car!

It is a lump not an indent right?

Did you have any problems with your window?

Yeah winter!

It is indeed a firm lump. Window operates without issue.

No weird noises when you close the door? Sure looks to have come from the inside somehow. Probably the most bizarre thing I have seen on this forum (and I have seen some weird shit). Probably going to have to pull the door panel to see what is going on in there.

So far it appears to be 100% cosmetic. The door and window operate fine, no changes in panel gap. Nothing amiss on the interior of the car. I will schedule it with Toyota tomorrow. Perhaps it is a super simple problem?

Thanks for your help guys.

No doubt when we hear what it is it will indeed be simple but damn I am baffled.

not sure what would be simple lol. i dont think a PDR would fix that satisfyingly especially considering it is bulging outwards...would have to get a new door otherwise.

Has your car been exposed to blast over pressure or vacuum? Betcha' you got water in there on something and it froze.