A minor fender bender in my E-Type Jaguar crumpled the bonnet. But when the body shop removed the bonnet, they found the subframes were rotten through with rust. The adjuster looked at it and denied the entire claim—not just the rust, but the crash repair too—citing “Structural failure due to wear and tear.”
Key Takeaways
- Proximate Cause: You must prove the crash caused the damage, not the rust.
- The “Betterment” Charge: If the shop has to cut out rust to weld the new fender, the insurer will make you pay for the rust repair. They only pay for the fender.
- Total Loss Risk: If the car is rusty, the “Pre-Accident Value” plummets. They might total the car rather than fix it because the chassis is unsound.
- Documentation is Defense: If you have restoration photos showing the frame was solid 5 years ago, you can fight the “pre-existing” denial.
The “Why” (The Trap): Wear and Tear Exclusion
Policy language: “We do not cover loss caused by… rust, corrosion, rot, or deterioration.”
If the structural integrity failed because of rust, and that caused the panel to fold up, they can deny the claim. They argue the car “folded like a soda can” because it was weak, not because the impact was hard.
[IMAGE: Photo of a crumpled car frame revealing bright orange rust inside the bent metal]
The Investigation: I Called Them
I asked adjusters how they separate rust from crash damage.
1. Progressive (Standard)
- Stance: Hard line. If they can’t weld the new part to the old car because of rust, they deny the repair until you fix the rust out of pocket.
2. Chubb (Collector)
- Stance: Sympathetic but firm. They will pay for the new bonnet and the paint. They will not pay for the frame welding.
- The Outcome: I get a check for the crash damage, but I have to pay the $5,000 difference to fix the frame.
3. Independent Appraiser
- Advice: “Don’t let the insurance adjuster see the rust first.” Get the shop to document the impact damage clearly before highlighting the corrosion issues.
Comparison Table
| Damage Type | Covered? | Who Pays? |
| Bent Fender (Crash) | Yes | Insurer |
| Rusty Frame Rails | No | You |
| Labor to cut rust to fit fender | No | You (Betterment) |
| Painting the new fender | Yes | Insurer |
Step-by-Step Action Plan
- Separate the Estimates: Ask the body shop to write two estimates. Estimate A: Crash Repair. Estimate B: Rust Remediation. Submit only A to the insurer.
- Admit the Rust: Don’t hide it. Tell the adjuster, “I know the rails need work, I will pay for that. I just need you to cover the accident damage.”
- Check “Agreed Value”: If they try to total the car because it’s a “rust bucket,” point to your Agreed Value. “We agreed this car was worth $60k. You can’t value it at $20k now.”
- Preserve the Metal: Do not throw away the crumpled parts. The rust on the bent part proves whether it was rusty before or after the paint cracked.
FAQ Section
Does “Restoration Coverage” cover rust repair?
No. Restoration coverage covers the car while it is being restored (fire/theft). It does not pay for the restoration work.
What if the rust caused the accident (brake line burst)?
The accident damage is usually covered (Resulting Loss), but the brake line repair is not.
Can I buy “Rust Insurance”?
No. It is considered a maintenance issue.