Hi all.
The pics say it all. On all the car, this is the worst rust and it is on the passenger (american drivers) side.

So, I would really love to to save it because doors over here can cost about AU$800.

Anyway I could repair this door?

Thanks all.

 

Since your probably don't have much access to a replacement considering your location, I'd say you better fix it. It can be saved, but it'll take a bit of work.

 

POR15 or similar product + some welding and it can be saved.

 

Cool. What's the best way to go with the welding?
The por stuff i have used before so that's not a problem.

Cheers all.

 

For stuff like this I usually cut all the bad metal away and make paper templates of the new parts. Then trace it into sheet metal and tack and shape with a hammer. After I connect the tacks and grind.

You can use whatever welder you want but a tig would probably be the easiest. After welding use the POR system as usual with the metal ready and the POR paint.

 

Cheers for the info. As welding is not my forte, would there be any other way of fixing, like this 3M panel bond stuff? Where would the replacement metal be put? On the inside of the door and then filled, sanded etc from there?

Which bits would need new metal?

Sorry for the dumb questions.

Cheers.

 

I am not sure about 3m panel bond I have never used it. I have had good luck with POR 15s putty and different firber glasses.

My only concern would be the area by the hinge and making sure it was strong. If the metal is not to bad there at least put some fiber glass inside the door.


The rest you can probably putty and sand.

 

Ok. Going to attempt this this weekend so this is the order as I see it (feel free to correct my mistakes:-)
I remove any loose rust, then por15 the rust left behind.
The area away from the hinges - Can I just fibreglass behind the hole and patch up from there?
As for the hinge area - Por15 the rust and reinforce behind (again with fibreglass)?

Cheers

Jonno

 

Anywhere you have a hole or thin metal due to rust needs to be cut out and repaired by welding in new metal. The hinge area is an important structure to disperse the force applied by the hinge. Fiberglass repair behind/near the hinge isn't a good idea.

 

Get the rust off and get some pics of the hinge. If the hinge has issues get it welded. The bottom can be glassed.