Aluminum Door Panel warping

[rryan]

Hello everyone. I took delivery of my R1S back in May 2023. One of the many items to address with my first service appointment was some warping of the front door panels underneath the handles.

Unfortunately, when picking up vehicle 2 weeks later, the SC (Costa Mesa) said it was within factory spec.

I called one PDR shop recently who just happened to do work for Rivian. He doesn’t want to touch it.

Needless to say, this has been bugging the heck out me every time I approach the car, and in the right light it looks like the car has been hit.

Has anyone here experienced the same problem and have a recommended solution? Launch another service request with Rivian?

Thanks!

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[Prime]

Hello everyone. I took delivery of my R1S back in May 2023. One of the many items to address with my first service appointment was some warping of the front door panels underneath the handles.

Unfortunately, when picking up vehicle 2 weeks later, the SC (Costa Mesa) said it was within factory spec.

I called one PDR shop recently who just happened to do work for Rivian. He doesn’t want to touch it.

Needless to say, this has been bugging the heck out me every time I approach the car, and in the right light it looks like the car has been hit.

Has anyone here experienced the same problem and have a recommended solution? Launch another service request with Rivian?

Thanks!

On a much more minor scale. It’s due to people pushing towards the center of the door instead of at the edge of the door. Due to how thin the aluminum is inevitable to some degree unless you’re careful.

 

[rryan]

On a much more minor scale. It’s due to people pushing towards the center of the door instead of at the edge of the door. Due to how thin the aluminum is inevitable to some degree unless you’re careful.

Thanks for the response! I’m aware of using the door edge to close and not the handle. It came this way on delivery. Maybe someone did this prior.

 

[Prime]

Thanks for the response! I’m aware of using the door edge to close and not the handle. It came this way on delivery. Maybe someone did this prior.

Ah sorry. Missed that. Not normal. You should open a ticket and explain it was there on delivery. It can be fixed with paintless dent repair. Good luck.

 

[LittonLad]

I had exactly the same issue on my R1T at delivery on both sides (one side to a much lesser extent) and have had the SC look at it twice. The second time (Chelsea MA) the tech told me it was due to how the aluminum is stressed on the door. We walked around the lot and spot checked multiple Ts and Ss, and a majority had a similar issues, although some much less obvious. At that point I dropped the issue and have learned to live with it.

 

[rryan]

I had exactly the same issue on my R1T at delivery on both sides (one side to a much lesser extent) and have had the SC look at it twice. The second time (Chelsea MA) the tech told me it was due to how the aluminum is stressed on the door. We walked around the lot and spot checked multiple Ts and Ss, and a majority had a similar issues, although some much less obvious. At that point I dropped the issue and have learned to live with it.

That is what the tech said to me as well. Ugh. I’m still holding out for hope there is a solution. Until then I will live with it. Thanks for sharing your experience.

 

[R1Thor]

I had this issue develop on my passenger door and it became really noticeable about 3 months into ownership.

Rivian Advisors hemmed and hawed about it (never blamed me, but never took ownership for it). I eventually had my friendly neighborhood detailer's favorite PDR guy correct it for me. In hindsight, I probably should've made Rivian deal with it, but I really didn't want to be without my truck and abhor having to drive 2.5 hours to service... (and didn't like the conversations I was having that made me feel like they weren't going to own it, despite conversations on Reddit about this being a 'known' flaw).

 

[Herb]

That is what the tech said to me as well. Ugh. I’m still holding out for hope there is a solution. Until then I will live with it. Thanks for sharing your experience.

I call BS. You are guys are too nice and shouldn't accept this. Heck, a Model T had better bodywork, even some CTs have straighter panels. There are millions of aluminum car doors that look perfect (F150). Audi mastered it 30 years ago. If this is because of the metal, then there was a material defect or a manufacturing problem. But it does look like somebody pushed the door in. No way it left the factory like that! In all likelihood it happened during delivery. If Rivian thinks this door is acceptable, why don't they take it back and give you another one?

 

[rryan]

I had this issue develop on my passenger door and it became really noticeable about 3 months into ownership.

Rivian Advisors hemmed and hawed about it (never blamed me, but never took ownership for it). I eventually had my friendly neighborhood detailer's favorite PDR guy correct it for me. In hindsight, I probably should've made Rivian deal with it, but I really didn't want to be without my truck and abhor having to drive 2.5 hours to service... (and didn't like the conversations I was having that made me feel like they weren't going to own it, despite conversations on Reddit about this being a 'known' flaw).

Thanks for sharing. Good to hear PDR fixed it for you. I’m going to keep checking around for reputable PDR shop in my area.

I had someone tell me some rivians have a door handle component that is epoxied to inside of door panel causing it to suck in just a bit.

 

[iansriv]

Open ticket. That looks weird.

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