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Presently, three common methods are used to examine perforation corrosion performance of auto body panel materials. They are field surveys, accelerated proving ground tests, and hem flange cyclic tests (laboratory). Typically, each method has a variety of shortcomings (i.e. time, correlation, cost, statistical validity, test sample size restrictions, etc.). The mini-door design is being evaluated as a way to minimize these shortcomings. Due to size and configuration, many types of materials can be tested under similar conditions (processing and testing) in a shorter time span and at less cost. The mini-door configuration is being evluated on Proving Ground road and laboratory tests. The use of the mini-door as a material development and testing tool dramatically reduces vehicle test costs.