Buying a used car an notice rust? Learn why rusty cars less safe
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Rusty cars less safe in crashes

Those little orange spots on your car aren’t just unsightly, they could mean the structure of your car is slowly disintegrating.

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Steel. It’s a versatile material used extensively in modern car construction. Steel does have a downside though, left unprotected, the iron in the metal begins to oxidise forming what we know as rust. As the rust starts to take hold, components begin to corrode and lose integrity. Eventually, parts can fail entirely.

A Swedish insurance company recently commissioned ANCAP’s European counterpart to crash test older, rusty vehicles. The results are startling.

What's in this guide?

Rust causes weakness in cars

A British crash test laboratory conducted the assessments. Two models were chosen, the first-generation Mazda6 and the Mark 5 VW Golf, both produced from 2003-2008. Engineers selected these cars as they are representative of two different vehicle classes, but also commonly suffer from rust issues in critical areas.

Engineers found that rust causes metal to lose structural integrity and become weak. So an older vehicle doesn’t perform as it did when initially crash tested. This problem is further compounded when you consider ageing models feature fewer modern safety technologies.

Rusting, older car presents 20% higher risk of death

The Mazda6 did not perform well under the test.

In a frontal impact collision, the crash test dummy’s head made contact with the steering wheel after the airbag bottomed out. The dummy then bounced off the wheel into the door upright. The car’s body shell deformed in an unexpected manner and the floor caused lower leg injuries when spot welds failed and separated. Crash engineers noted that a weak floor could allow objects to pierce the vehicle’s underside and enter the cabin, with disastrous consequences.

Over the decade since production ceased, Mazda's sedan dropped from a weak four out of five to a weak three points. In total, it shed 8 points on NCAP’s scoring system.

Researchers concluded that in a heavily corroded vehicle, occupants had a 20% higher likelihood of dying in a crash.

The Golf, on the other hand, performed remarkably, losing only a single point from its original crash rating. This underlines a key finding of the study, that each car rusts in a unique and individual way due to a range of variables, making them unpredictable.

The laboratory tested both cars to the same standards as when new, not to more recent and stringent evaluations.

Identifying rust

Manufacturers apply anti-corrosion paints to crucial components at the factory, but eventually stone chips and wear cause coatings to break down. Drivers living in coastal areas will suffer accelerated oxidisation, thanks to a high salt content in the air. Boats and vehicles taken onto the beach also suffer badly with rusting.

You can identify rust by bubbling, flaky paint and a red/brown pitting. Rust generally starts small but will get worse if left untreated. If you are buying a car, take time to look underneath and examine the condition of structural metal components. If you see ragged holes and lots of loose corrosion, the car may be too far gone.

It’s possible to use a hammer to ascertain the condition of metal surfaces. If you tap the steel and it produces a sharp, defined ring, the metal should be in sound condition. If tapping makes a dull thud, the steel has most likely started corroding.

Preventing rust

Once the rust on a part reaches a certain point, it will need replacing or repairing by a professional welder. You are far better off preventing rust by taking some simple precautions.

  • If you drive in seawater or even on the beach, take time to wash the vehicle off with fresh water. This eliminates salt which is a catalyst for oxidisation. Clean the underside of your vehicle too.
  • If you spot surface rust (light rust), abrade the surface to remove pitting and flakes, then overpaint with a corrosion inhibitor and anti-corrosion primer/top coat. Look for marine grade products as these often perform the best.
  • Greasing nuts and bolts with a non-metallic lubricant can ward off rust and make removal easier. There are also anti-corrosion sprays available.
  • If you notice a window, door or seal is leaking, get it fixed right away!

Newer cars are safer

Research shows that newer vehicles are statistically safer. You can use our car loan comparison to find a great deal on a modern car. We’ve also written about Australia's safest cars. Use ANCAP or used car safety ratings to find out how your car performed when crash tested.

Drivers will find our article on what happens to your body in a car crash a sobering read.

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Name Product Interest Rate (p.a.) Comparison Rate (p.a.) Monthly Repayment View Details CTA
Plenti Car Loan
Plenti Car Loan
From
4.89%
(fixed)
5.44%
You'll receive a fixed rate from 4.89% p.a.
Borrow up to $100,000 with a Plenti Car Loan and benefit from no early repayment or exit fees.
You'll receive a fixed rate from 4.89% p.a.
Borrow up to $100,000 with a Plenti Car Loan and benefit from no early repayment or exit fees.
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Loans.com.au - New and Dealer Used Car Loan
Loans.com.au - New and Dealer Used Car Loan
From
4.67%
(fixed)
5.22%
You'll receive a fixed rate from 4.67% p.a. based on your risk profile
Finance a new car and benefit from features such as fast approval, no ongoing fees and an optional balloon payment. Settle the loan before 30 November 2021 and enter the draw to win a $1,000 fuel gift voucher. T&Cs apply.
You'll receive a fixed rate from 4.67% p.a. based on your risk profile
Finance a new car and benefit from features such as fast approval, no ongoing fees and an optional balloon payment. Settle the loan before 30 November 2021 and enter the draw to win a $1,000 fuel gift voucher. T&Cs apply.
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IMB New Car Loan
IMB New Car Loan
4.99%
(fixed)
5.34%
You'll receive a fixed rate of 4.99% p.a.
A low minimum borrowing amount of $2,000 that you can use to purchase a new car or one that's up to two years old.
You'll receive a fixed rate of 4.99% p.a.
A low minimum borrowing amount of $2,000 that you can use to purchase a new car or one that's up to two years old.
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Credit Concierge Car Loan
Credit Concierge Car Loan
From
3.85%
(fixed)
4.91%
You'll receive a fixed rate of 3.85% p.a. with a comparison rate of 4.91% p.a.
Get access to over 20 providers to fund a new or used car.

You'll receive a fixed rate of 3.85% p.a. with a comparison rate of 4.91% p.a.
Get access to over 20 providers to fund a new or used car.

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MoneyForJam Car Loan
MoneyForJam Car Loan
From
3.25%
(fixed)
5.82%
You'll receive a fixed rate from 3.25% p.a. based on your risk profile
Borrow between $5,000 and $120,000 with loan terms up to 7 years to finance a new or used car. Get access to more than 40 providers.
You'll receive a fixed rate from 3.25% p.a. based on your risk profile
Borrow between $5,000 and $120,000 with loan terms up to 7 years to finance a new or used car. Get access to more than 40 providers.
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NRMA New Car Loan
NRMA New Car Loan
From
4.99%
(fixed)
5.69%
You'll receive a fixed rate from 4.99% p.a.
Purchase a new or used car up to 2 years old and benefit from a fixed rate and no monthly fees. Pre-approval available within 5 business hours.
You'll receive a fixed rate from 4.99% p.a.
Purchase a new or used car up to 2 years old and benefit from a fixed rate and no monthly fees. Pre-approval available within 5 business hours.
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Wisr Secured Car Loan
Wisr Secured Car Loan
From
4.74%
(fixed)
5.01%
You'll receive a personalised interest rate from 4.74% p.a. to 16.01% p.a. based on your risk profile
A flexible car loan from $5,000 - $63,000 with personalised rates and rewards for strong credit customers.

You'll receive a personalised interest rate from 4.74% p.a. to 16.01% p.a. based on your risk profile
A flexible car loan from $5,000 - $63,000 with personalised rates and rewards for strong credit customers.

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RACV New Car Loans
RACV New Car Loans
From
4.99%
(fixed)
5.69%
You'll receive a fixed rate from 4.99% p.a.
A larger loan of $5,000 or more to help you buy a new or used car. 5-hour pre approval available and no ongoing fees.
You'll receive a fixed rate from 4.99% p.a.
A larger loan of $5,000 or more to help you buy a new or used car. 5-hour pre approval available and no ongoing fees.
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NAB Personal Loan Unsecured Fixed
NAB Personal Loan Unsecured Fixed
From
6.99%
(fixed)
7.91%
You'll receive a fixed rate between 6.99% p.a. and 18.99% p.a. ( 7.91% p.a. to 19.83% p.a. comparison rate) based on your risk profile
An unsecured loan up to $55,000 you can use for a range of purposes and pay off over up to 7 years. Note: Majority of customers will get the headline rate of 12.69% (13.56% comparison rate) or less. See Comparison rate warning in (i) above.
You'll receive a fixed rate between 6.99% p.a. and 18.99% p.a. ( 7.91% p.a. to 19.83% p.a. comparison rate) based on your risk profile
An unsecured loan up to $55,000 you can use for a range of purposes and pay off over up to 7 years. Note: Majority of customers will get the headline rate of 12.69% (13.56% comparison rate) or less. See Comparison rate warning in (i) above.
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OurMoneyMarket Car Loan
OurMoneyMarket Car Loan
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5.35%
(fixed)
5.65%
You'll receive a fixed interest rate from 5.35% p.a. to 14.99% p.a. based on your risk profile.
Borrow between $2,001 and $75,000 to finance a new or used car up to 10 years.
You'll receive a fixed interest rate from 5.35% p.a. to 14.99% p.a. based on your risk profile.
Borrow between $2,001 and $75,000 to finance a new or used car up to 10 years.
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CUA Secured Fixed Car Loan
CUA Secured Fixed Car Loan
6.79%
(fixed)
7.16%
You'll receive a fixed rate of 6.79% p.a.
A secured loan with a high maximum borrowing amount up to $100,000. Redraw facility and no monthly fees.
You'll receive a fixed rate of 6.79% p.a.
A secured loan with a high maximum borrowing amount up to $100,000. Redraw facility and no monthly fees.
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Latitude Personal Loan (Secured)
Latitude Personal Loan (Secured)
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5.99%
(fixed)
7.26%
You'll receive a fixed rate between 5.99% p.a. and 21.99% p.a. based on your risk profile
Lock in a competitive fixed rate when you offer security. Loan can be used for any purpose and repayments are flexible. You can check your interest rate before applying with no impact to your credit score.
You'll receive a fixed rate between 5.99% p.a. and 21.99% p.a. based on your risk profile
Lock in a competitive fixed rate when you offer security. Loan can be used for any purpose and repayments are flexible. You can check your interest rate before applying with no impact to your credit score.
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Stratton Finance New Car Loan
Stratton Finance New Car Loan
From
3.85%
(fixed)
4.05%
You'll receive a fixed rate from 3.85% p.a. depending on the lender you are approved with
Apply for up to $250,000 and use cash or trade in a vehicle to use as a deposit. Optional balloon payment available.
You'll receive a fixed rate from 3.85% p.a. depending on the lender you are approved with
Apply for up to $250,000 and use cash or trade in a vehicle to use as a deposit. Optional balloon payment available.
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SocietyOne Car Loan
SocietyOne Car Loan
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6.99%
(fixed)
6.99%
You'll receive a fixed rate between 6.99% p.a. and 20.49% p.a. based on your risk profile
A loan from $5,000 to use for a range of purposes. Benefit from no ongoing fees and no early repayment fee.
You'll receive a fixed rate between 6.99% p.a. and 20.49% p.a. based on your risk profile
A loan from $5,000 to use for a range of purposes. Benefit from no ongoing fees and no early repayment fee.
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Driva Car Loan
Driva Car Loan
From
3.95%
(fixed)
5.1%
You'll receive a fixed rate from 3.95% p.a.
Borrow up to $250,000 with loan terms from 1 to 7 years. Get access to a range of lenders.
You'll receive a fixed rate from 3.95% p.a.
Borrow up to $250,000 with loan terms from 1 to 7 years. Get access to a range of lenders.
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NRMA Used Car Loan
NRMA Used Car Loan
From
6.49%
(fixed)
7.19%
You'll receive a fixed rate from 6.49% p.a.
Finance a used car with NRMA and benefit from a fixed rate term and no monthly fees. Pre-approval available within 5 business hours.
You'll receive a fixed rate from 6.49% p.a.
Finance a used car with NRMA and benefit from a fixed rate term and no monthly fees. Pre-approval available within 5 business hours.
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Symple Loans Personal Loan
Symple Loans Personal Loan
From
5.75%
(variable)
6.47%
You'll receive a personalised interest rate from 5.75% p.a. to 25.99% p.a. based on your risk profile
Borrow up to $50,000 to pay for what you need.
You'll receive a personalised interest rate from 5.75% p.a. to 25.99% p.a. based on your risk profile
Borrow up to $50,000 to pay for what you need.
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Name Product Roadside Assistance Accidental Damage Storm Choice of Repairer Agreed or Market Value
Budget Direct Comprehensive
Budget Direct Comprehensive
Optional
Optional
Agreed or Market
Finder's summary: Awarded the 2019 Finder Award for the Best Value Car Insurance, this policy offers solid coverage at a low cost plus you will get 15% discount on first year's premium when you take out a policy online. Budget Direct’s claims service has received a 4.2/5 based on nearly 5,000 customer reviews.

Who it might be good for: People who want a comprehensive policy without breaking the bank.
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Bingle Comprehensive
Bingle Comprehensive
Market
Finder's summary:Bingle consistently comes up as one of the cheaper insurers out there. It only covers the basics, so you don't get to choose your own repairer, you're not covered for personal items in the car and unless you add it as an option, you won't get a hire car if your car is stolen. But this keeps its premiums low.

Who it might be good for: Someone who wants a low-cost option that covers them for the basics.
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Coles Comprehensive
Coles Comprehensive
Optional
Agreed or Market
Finder's summary: Coles have two-tiers of comprehensive car insurance to choose from. You'll earn double flybuys points at Coles supermarkets and you can get $10 off your Coles grocery bill every time you redeem 2,000 Flybuys points. If you're over 30, you can get roadside assistance free for a year.

Who it might be good for: Coles customers and Flybuys collectors.
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Poncho Comprehensive
Poncho Comprehensive
Agreed
Finder's summary: Poncho works like a monthly subscription – you pay monthly and can cancel and leave at any time. You can also list multiple cars and drivers under one policy, making it ideal for families and groups living together under one household.

Who it might be good for: People who want their car insurance month to month.
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Woolworths Comprehensive
Woolworths Comprehensive
Optional
Agreed or Market
Finder's summary: Woolworths catches our eye due to some unique perks like a price-beat guarantee, where it'll beat any current comparable comprehensive renewal notice if you're over 25. You'll also get 10% off your grocery shop once a month and can add roadside assistance onto your policy for just $7.35 per month.

Who it might be good for: Woolworths shoppers and those that want to take advantage of its price-beat guarantee.
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Qantas Comprehensive
Qantas Comprehensive
Optional
Optional
Agreed or Market
Finder's summary: You'll be able to choose how comprehensive you want your cover to be with optional extras like choice of repairer and the option of agreed or market value. Plus earn Qantas Points for joining and paying your premium. Sign up by 2 May 2021, you can earn up to 30,000 Qantas Points (points awarded will be based on your premium). T&Cs and eligibility apply.
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ahm Comprehensive
ahm Comprehensive
Optional
Both
Finder's summary: ahm comprehensive car insurance lets you choose higher excess to reduce your premiums plus you can get up to 15% off when you purchase a new car insurance policy. T&Cs apply. Additionally, their Fixed Kilometre Plan can save you up to 30% compared to their standard comprehensive cover.

Who it might be good for: People who drive less than 15,000 km per year.
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Virgin Comprehensive
Virgin Comprehensive
Optional
Optional
Agreed or Market
Finder's summary: Finalists for the 2019 Finder Awards for Best Value Car Insurance, Virgin Comprehensive provides a good level of cover for a decent price. Get 15% off on your first year’s premium when you purchase a new eligible comprehensive car insurance online. T&Cs Apply.
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