Rust Prevention

You own a Range Rover and always stand back and look in admiration just after you've washed it.  You are well aware the outer panels are made from an aluminium alloy which will not rust and this gives you confidence as you briefly think of the rusted doors and sills of other cars you have owned.

Beware, beneath that alloy shell is a steel chassis and steel framework which could be slowly turning into iron oxide.  I have seen Range Rover doors which look good on the outside but are completely rusted out in the internal frame.

Land Rovers can hide rust very well and with extra preventive maintenance the rust will remain a minor problem and in some cases it can  be eliminated.  A highly recommended anti rust system which  injects a liquid wax substance into all crevices and inside chassis and framework seems to be very popular in certain countries,  while this type of system sounds very good it has a limited success rate if all the surfaces are not properly prepared. Some hard to get at areas are nearly impossible to access for preparation and if you don't prepare the surface properly don't waste your money.

Rust is caused by moisture being trapped in certain parts of your RR.  Automotive designers incorporate seals to stop the ingress of water, these seals need replacing as part of your normal maintenance program and include door window seals, tailgate seals etc.  These seals also can cause rust by trapping moisture. Most rust problems could have been prevented if the owner did a yearly rust check.  This does not mean you look for rust, you need to identify the potential rust problem before it starts.   Below is my yearly checklist.
 

•  Check all window glass for sealing and repair as required.

• Thoroughly clean underbody and chassis while seeking trapped mud.

• Check underbody and chassis for rust and repair as required.

•  Remove, check and refit all body drain plugs.

• Remove all door trims, inspect inside of door for moisture, dust and flaking paint- clean inside of doors thoroughly and repaint if required.  If dust or moisture is evident seek the source of entry and repair.

• Remove internal backing of lower tailgate, clean the surface removing all dust build up from the lower portion, if paint surface is scratched, flaky or rusted prepare surface and repaint/repair.  Remove plates from tailgate and inspect inside, clean dirt and dust.  If paint is flaky or rust is evident prepare surface and repair/repaint.

• Remove panel strips from upper tailgate,  check seals and replce if faulty and thoroughly clean, repair rust and repaint any area as required.

• Remove all floor coverings and floor sound proofing, check thoroughly all floor areas including the rear parcel area, if any moisture is evident track the source and eliminate further moisture ingress.  Check for flaky paint and repaint as required.

This yearly check is not a 1/2 hour job, to do it properly including repairs can take one or two weekends.  Cleaning the underbody of the car requires a steam clean or at least a hot high pressure clean and don't forget the inside of the chassis rails.

If you live in a part of the world that has winter icy roads and your city dumps 100s of tonnes of salt to eliminate the problem then you are in trouble.  The only way I see you having any success with rust reduction is a daily car wash, especially the underbody.  I understand the last thing anyone wants to do is wash the underbody of a car in 2 foot of snow with an outside temperature of --30 degrees but if the salt is not removed the Range Rover will rust.

I could never understand why some people would go to the trouble and expense of galvanizing their chassis until I heard of some horror stories regarding chassis rusting out under 4 years in these salt infested areas.

For further reading try these sites: 
ZRC Worldwide zinc coating information. 
Homework Brief science lesson on rust.