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Dealing with this nonsense...for anyone that has not made their way over to the other forum...thoughts are welcome https://www.mustang6g.com/forums/threads/tear-in-frame.196741/

You mean to tell me booger welds do not scream "reputable"???

I have a very good quality body shop a few miles from me that I have used in the past. It may be worth their hourly rate to just take a tail light out, get it on a lift, and get their professional opinion. Or, I start with the dealership if this is truly an awful Ford QC issue.

I was given a carfax by the selling Ford dealer, which was clean. I am the 3rd owner. I don't know of any recourse unless selling dealer knowingly lied to me, which would be fraud.

That is discouraging (no offense). Your lines look great. Your driver side is "worse" than the passenger side, but obviously way better than mine. Someone else mentioned a rear end slap and quick repair, and that may be likely here.

Here are more pics... Fearing an unreported repair has me in a bad sort of way. 1) value is obviously affected, 2) I bought the car August 2022, so there is no recourse with selling dealer unless they knew about damage and advertised it as clear to me (plus I'd have to see what Illinois statute...

Even if no insurance was involved, I would imagine most reputable body shops report to whatever system is CarFax. I mean, I had curb rash repaired and I see that on the recent carfax pulled.

pain in the ass to pull? What would I be looking for?

subtract cost of block, so what...3k for predator block and less for voodoo block?

Looks like I didn't take a pic of that side, I will get one, but I saw no pitting, tearing, or holes on driver side.

Obviously OP's build will be less, but if you did not have a block to start with, then close to $13k for a sleeved predator block, reuse 350 heads, and buy Predator cams from ford for ~1k.

As Biggus Dickus pointed out, I am attaching these pictures where it looks like more failure in the same corner.

I tend to agree, but at the least I think I will let Ford take a look at it first. This seems like a bizarre material defect.

I thought I saw two more pin holes closer to the rear of the seam.

Hoping for the best and that I get a sympathetic warranty advisor, but we will see.

I appreciate the discreteness.

I am going to schedule an appointment with my local ford dealer and try to go through them. They have a good body shop, so hopefully this is just a big nothing burger.

Cutting is the absolute last thing I want to do, especially if it is on my dime. I like the idea of rust protectant, seam sealer, and paint.

corrosion warranty expired at 5 years, so I am all out of warranty (except for emissions devices, lol), but this looks to be an obvious material defect.

Now I wonder what the proper repair here is