Looking to get some rust repair advice.?

Question

I have a couple of rust spots on my driver side door that appeared following this past winter.  I'm going to be repairing them on an upcoming weekend and was looking for some tips and advice.  Here's some pictures of the door:

http://img32.imageshack.us/img32/2252/1000092ad.jpg
http://img69.imageshack.us/img69/62/1000093r.jpg
http://img24.imageshack.us/img24/7518/1000094ru.jpg

My plan is to grind / sand away at the rust until i get to clean metal, or if its rusted all the way through i'm cutting it out and welding a piece of 20 gauge sheet metal in.  And use some bondo to fill in the low spots, prime and paint.

I'm really looking for some advice when it comes to painting, I don't want to see any kind of noticeable areas where you can tell new paint was applied.  What do you guys think about sanding the entire door to scuff it up and put a fresh coat of paint on the entire door?

Another option I'm considering is to rent a sand blaster and sand blast the entire door and then do my rust repairs prime and paint the whole thing.  I'd really like to avoid sandblasting if I can get away with just scuffing up the paint and putting a new coat on the door.

Thanks!

nitrobreath2000 · Accepted Answer

From the pictures you provided it appears that your rust is currently pitting the metal door skin and bubbling under the paint. Both conditions are considered severe rust defects. Your ideas to cut out the rusted areas and weld in new metal are the best. Sand Blasting is a viable option but remember you are removing all the old paint so repainting will require the requisite 3 coats of primer/surfacer and then a proper application of topcoat. On the other hand, if you don't sand blast and just sandpaper the other existing areas to feather them into the repair, it will be less work. 

Always repaint in "panels" this will minimize the appearance that a repair job has been done.

Good Luck

br549 · Answer

You have a serious rust issue there. What is happening is the door drains have failed (water gets into all doors with roll up windows). The rust is also in the inner frame of the door meaning you are rusting from the inside out. 

This is a fixable problem but needs to be done right. The proper way would be to re-skin at least the lower section of door or use a new shell.  A used door from here: http://car-part.com/ may be the easiest way in the long run!

If you do repair the door yourself, before any filler use an epoxy etch primer, then filler, then a high build primer to get level with the surrounding paint. If the old paint on the door is sound, you can degrease, scuff and paint right over it with good results. To acheive a non noticeable blend, you can use a base/clear system and blend into adjacent panels. No matter how good the mix, just painting one panel will alwys be noticeable.

? · Answer

Its a real decrease back woods thank you to do it. which will artwork, yet I propose making use of physique filler on the exterior, some thing like bondo. The physique filler will make it seem extra like metallic, because of the fact I dont think of you will have the skill to get that ingredient inspected with rust holes. you will possibly be able to desire to apply fiberglass in case you wanted to bypass a notch above the increasing foam and bondo trick. i've got considered human beings use duct tape and purely spray paint over it to bypass inspection.

Anonymous · Answer

rust repair advice
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Looking to get some rust repair advice.?

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