2004 Mazda RX-8 2.6L Petrol · S2 DOA

This Mazda RX-8 carries a significant history of structural corrosion, culminating in a major MOT failure in October 2023 due to extensive deterioration of the integral body structure. Specific failures were recorded on the offside rear quarter panel, offside rear end of the sill, and offside front outer sill, all corroded to the extent that structural rigidity was significantly reduced. While the vehicle subsequently passed a retest in November 2023 with no defects recorded, this incident underscores a persistent and serious underlying issue, as earlier tests in 2018 and 2019 also noted advisories for integral body structure corrosion and an inability to check for corrosion due to underseal, which can often mask underlying rust. The recent clean pass indicates the immediate structural issues were addressed, but the long-term integrity remains the primary concern. The vehicle’s recorded mileage of 101,663 miles over approximately 22 years translates to an average annual accumulation of around 4,621 miles, which is low for its age. This usage pattern suggests either periods of lighter use or extended periods of standing, neither of which inherently guarantees better mechanical condition. While lower mileage can reduce wear on some components, prolonged inactivity can lead to issues such as perished rubber components, seized brake calipers, or fluid degradation, though the MOT history does not explicitly flag these as chronic problems. The mileage accumulation appears relatively consistent between tests, with no significant gaps indicating long periods off the road, other than the short interval between the 2023 failure and subsequent pass for repairs. The paramount area for inspection on this vehicle is the structural integrity, particularly focusing on the areas flagged for major corrosion in 2023: the offside rear quarter panel, the offside rear end of the sill, and the offside front outer sill. Any repairs undertaken to rectify these major defects must be thoroughly scrutinised for quality, extent, and finish. Look for signs of fresh welding, excessive filler, or new underseal that might be concealing further issues or poor workmanship. It is crucial to check the entire sill length and surrounding bodywork for any further signs of corrosion, especially given the earlier advisories regarding rear sills and the difficulty in assessing corrosion due to underseal. Beyond the structural concerns, a comprehensive inspection should address other historical advisories. Check for any current signs of an engine oil leak, as one was noted in 2020. Inspect all brake pipes, particularly at the rear, for any signs of corrosion or deterioration, following the 2020 advisory. Examine all tyres for even wear and sufficient tread depth, as a nearside front inner tyre was noted as worn close to the legal limit in 2020, which could indicate alignment issues or suspension wear. Finally, check the offside rear shock absorber for any oil misting or reduced damping effect, and listen for any knocking noises from the offside rear anti-roll bar linkage over uneven surfaces, as these components were flagged in earlier tests. Ensure the windscreen wipers clear effectively and the headlight washers are functional, as these were issues in the 2023 failure test.