The bottom of both doors are rusted, but not too bad. You can still sitck a finger through it. Should I replace both of them or is there a way to repair? Don't really look forward to removing the fender then the door, etc.

Thanks,
Brandon

 

Plasma cutter + mig welder + eletric sander = new door.

 

Get two used doors and save your self a large headache. I bought my doors for $50 and was done in about 4 hours.

Mark

 

If its possible to get some better used doors at a junk yard then go for it, You'll need at least 2 people for the job. OR you could cut out the rusted parts, sand away any rust inside of the door or out side the door, welding some sheet metal in their place behind the door skin "be careful with the heat, you dont want to warp the sheetmetal of the door and have waves all up and down" and fill in whats left of the hole with bondo and paint both sides so more rust wont occour again.

 

I have the same problem on my driver's door. As much as I want to keep the car original, I think I'll hit the junkyards soon.

 

Is there any problem with just removing the rust as best I can and having a big whole under the door?

Brandon

 

i really hope your just kidding.....

lol

um yea man, if you just cut the rust away then youll gain more rust cause now water will sit in side the door, if you have power windows it will possibly short out the motor. moisture will retain within there, youll hav emore rust develop. if you dont treat the spot you cut it will rust even more....

 

Actually...I wasn't kidding! Don't all f-body doors have small holes on the bottom anyway? Was just thinking of removing all the rust and treat, as you say, and leaving at.

Brandon

 

I think there are 2 1/8ths holes, one on each end of the door for draining, but not some gapping hole.

 

How about some epoxy putty and POR15?