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Every Subaru vehicle is built with a Rust Perforation Warranty (see dealer for warranty details). Subaru is able to offer such extensive corrosion protection because Subaru makes extensive corrosion-fighting efforts throughout the car-building process.
All cars start out as sheets of plain steel. The difference at Subaru is the conversion process of sheets of metal into cars. After the steel is stamped into body parts, sensitive areas are zinc-coated or galvanized. Galvanized steel has the ability to fight corrosion by "healing" small scratches in its surface. Some 77 percent of the Legacy bodies, for example, are made up of two-sided galvanized steel. Then the stampings are welded together by robots. Next, the body is thoroughly cleaned. Every trace of oil, dust and oxide is removed, leaving an impeccable surface onto which the protective layers can be applied.
The clean body is then dipped in a special primer, which is then bonded to the surface by "electrodeposition", in which the body and primer are electrically charged to opposite polarities. Since opposite charges attract, this pulls the primer into every seam and crevice of the body. Areas that conventional spraying methods might miss are covered, ensuring that corrosion is denied a foothold throughout the vehicle.
To further protect the body from corrosion, the rocker panels, underframe and wheel wells are coated with a polymer sealer. Asphalt noise insulation is added to reduce interior sound levels. Critical weld seams and all box channels are then coated with a special wax.
Finally, a multi-step coating is applied to all body parts to fight corrosion. The five coats are:
- Corrosion-resistant steel
- Electrocoating
- Primer seal
- Color base
- Clear coat
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