Looking to get some rust repair advice.?

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

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.

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.

rust repair advice

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