Ok so my doors are totally rotted to he** at the bottom lip where it folds over to the inner door panel. So i went and found two perfectly good doors off a 89 f body ta all powe every thing no spliced wires, motors all work nice and smooth and quick, locks actually work which im surprised, the only problem i have with the doors is the passenger side door. Where the rubber molding goes down it has some decent amount of surface rust all the way down im wondering how do i fix this without ruining the curve of the door. Im also not gonna use the rubber molding cause i like the sleek look it gives without it. Is there anyway to fix it or should i just sand it down and bondo over it. What would all of you guys and gals do ????

 

If its minor surface rust i would take and get as much of it off as i could then like a wire wheel or what ever. I found this product to work great its a acid but kind pricy its called Rust Mort. ive used it a lot and it kills the rust it creeps down into the places and stops it. you have to let it sit for 24 hrs though after applying. Just me but i would just skin cote the door that whole area block it out and go from there

 

Ive seen something about that rust mort also kinda pricy but seems totally worth it so u think its ok to wire wheel it as well and then send it out for paint

 

You can't really sand rust. No sandpaper in the world will get into the pits. The pits will continue to oxidize the metal, which will cause a bubble eventually after you've refinished everything.

Mediablast it with some crushed glass and a medium tip so you don't warp the panel. Spray some epoxy primer over the whole area. Let it cure. If it needs filler, rough it with 80 grit and skim coat it.

-- Joe