Yes the Fiesta is Galvenised that's why you get a 12 year corrosion warranty.
I think the Focus is as well but not Mondeo/KA

Thanks for the info Dave. At least it should'nt rust if I get the paintwork sorted out.

On the drivers door, theres a black arm/hinge thingy (techical term i know lol) that holds the door open and the bracket that is held to the bodywork keeps coming loose (the torx screw unscrews a bit). I try to tighten it up as much as it can but the bloody thing unscrews iteself after a few days. Anyone know what the problem is or how to fix it? It's not causing a rattle but it makes a knocking noise when opening/closing the door.

Do you mean any of these bits? (a pic of my drivers door hinge)

Check the black plastic bit on the outside of the car that runs the full height of the window. Mine passenger side rattles when driving along because the clips that hold the plastic has broken. I might shove some dum dum or no more nails etc to stick it again.
The picture below shows the area you need to check. If you can pull it out a few mm, then that is making the noise:

Yeah put it right tho dont leave it, the one on my old mk6 came off whilst i was driving on the motorway

Thanks everyone for your help!

Pink i meant that screw where the orange circle is. I'm not sure what is causing the rattle yet. Does that area with the red circle cause it?

*lol* No its the only picture I had of my door hinge. The red circle was to show someone where the rust can come through. I didnt have the original picture without it

I just went out to my car to have a look and I have rust there too. How feckin annoying... I'm gonna have to take it to the ford garage this time. Hope they dont screw it up.

I think everyone has the rust there. There isnt much that can be done for it. I wiped it off and keep an eye on it. A possible design fault maybe?

Ford are looking at my door when it has its first service. The rattle appears to be the window and obviously there is a threading problem on the hinge. They took some pictures of my car for the rust patch, discoloured bumper, vin and reg plate. The paint guy did'nt seem too interested in the side sills or chipped rear wheel arch and asked if I have dropped touchup paint on my bumper - as if! He said its very likley they will treat the door but are unsure about the bumper - depends on Ford apparently. At least they cant claim that I did'nt have the paintwork checked properly or anything like that because its less than 1 year old and the service book does'nt need stamping yet!

Ford have agreed to fix the discolouration on the bumper and the rust patch. I dont know about anything else but they are doing it on the 13th November.