How should I go about repairing this? Should I just replace the door and be done with it, or would a product like POR-15 work well? I would have to do very minor bondo work after the por-15 though....

 

The door is fine, you do not need to replace it.

What you will need to do is:
First: find a nice dry area to work.
Second, remove your handle & lock from inside.
third: take a D/A or other sander & grind off all the rust.
Fourth: Fill the area with either glazing puddy, or fast build primer, POR whatever you are sealing the metal with
Fifth, sand, & prime, then paint.

Clear coat & Polish for a nice finish

John

 

Thank you. I have very little experience in bosdy work, and same with my dad. I wasnt sure what would be the best approach. That seems like it will work good. Now to find time and space....

 

Agreed. The rust looks to be surface. I highly recommend using the POR15 as a sealer against the rust. Also, POR15 does not require it being sanded to to metal (just lose debris to be removed). I would still clear away as much rust as possible, then coat it with POR15. From there you can bondo or glaze (depending on need). Then:

 

Is that a crack or rip in the sheet metal door skin next to the lock? If so you should really have it welded if possible. Otherwise any body filler you use will just crack and chip away.

 

It is a crack. that is why I mentioned about replacing. I, unfortunately, do not weld. About how much would it cost to get it welded? How about for the whole job?

 

I did not see the crack when i first saw this. My appologies, thank *** for the other within this public service

You may want to go to local, REPUTABLE body shops in your area. Get estimates on the whole job (see if it's worth you messing with it). Plus, while you're there, ask them how THEY would fix this blemish.

I would say find somewhere to weld a support or a skin of some kind (but you'd have to do it behind the door panel, I would think). But I'm not sure how well it would work with the lock tumbler right there.

I do not know enough about body work yet to give a GREAT idea (another words, don't expect my idea to be the best or even correct). I think you're best bet might be some kind advice from some of your local body guys (plus they may see things that a picture does not tell)....

 

Is that also a crack near the bottom of the rusted out area? If so, the whole area may be thin. Check prices at local wrecking yards. I picked up a perfect door last year for $65 that only needs my hardware and pw motor added to it, and paint. Welding your door will probably run at least that much, and it is always possible that welds may re-crack if the metal is thin. Filling the cracks with putty will only last for a very short time before re-cracking.