Rust in doors

[zeus11]

G'day all

I pulled my door skins off to find some rust starting to form in the bottom of the front doors. I know this is a pretty common problem with the steel inserts in the door so im not that surprised.

There is 2 or 3 rust patches about the size of a finger nail. They dont appear to be too savage at this stage.

What is the best way to treat this? And how can I prevent the rust from increasing?

Cheers

[SimonM]

Found the same on mine yesterday. Will sit back and see what others recommend.

[hodgo]

Is to clean the rust with rust remover and wire brush, then use kneadit to patch the holes up. If the hole are too big put a bit of fly wire or other fine mesh in to it to support the kneadit, then file, clean kneadit back to an even surface then paint I also spray rust treatment through the frams before replacing.

Hodgo

[inside]

Maybe get the repair panels? 015 door repair section - YRM Metal Solutions Ltd (http://www.yrm-metal-solutions.co.uk/015-door-repair-section-11-p.asp)

[jorjatom68]

I installed an erps electronic rust prevention and use transmission fluid sprayed in the chassis and door frames. Drill a hole at the back end of each chassis rail and in the top and bottom of the door frame where the box section is used and spray the atf in to stop the rust from the inside. After a few doses the fluid creeps into all the areas that rover are too lazy to paint these days. Pre defender they painted the door frame then put the skin on to stop electrolysis but that cost too much.

[Bundalene]

If it was mine and the holes are small and not visible, clean up the area thoroughly with a wire brush or similar, unblock the drain holes in the bottom of the door, then apply several coats of POR15, KBS or similar

PPC - POR 15® Rust Preventive Paint (http://ppcco.com.au/prevention.htm)

RustSeal by KBS Coatings - Stop Rust with our Paint / Sealer (http://www.kbs-coatings.com.au/kbs-rustseal)

These are self leveling paint and find their way into the smallest of gaps.

Lastly, coat the whole area with a cavity wax such as a 3M product ARP1T or Sika-guard 554, or others

http://solutions.3m.com.au/3MContentRetrievalAPI/BlobServlet?locale=en_AU&lmd=1284345481000&assetId=1273667071216&assetType=MMM_Image&blobAttribute=ImageFile


http://www.sika.com.my/my-ind-pds-sikagard_554.pdf

If the damage is too great, - structural - it should be replaced. If it is just unsightly, clean the damaged area, fix it with panel beaters bog and then treat as above.

These products are available from most auto repair suppliers.

Erich

[zeus11]

Thanks for the replies and tips.

The rust isn't structural and only in its early stages but if left I'm sure it will end up being a bigger headache.

[Didge]

there's an interesting thread on this site about treating rust with a water and molasses solution - worth a read for those of us with more serious rust. Interestingly, I met a couple just two weeks ago who bought a nice new 130 ute and had no idea about the potential for rust; seems the idea that aluminium doesn't rust is well and truly alive; even though it still corrodes. I advised them to hit the doors with the best rust proofing they could find. As Erich mentioned above, the POR 15 is supposed to be the ants pants in sealing off rust forever (so I've been led to believe).
zeus11, I'd seal up the footwells and lower bulkhead areas as well if I were you. I just recently removed a windscreen "hinge" the other day and resealed it and you wouldn't believe how much water has stopped entering the passenger footwell. Have a look at the black foam porous seals that separate the windscreen panel and lower bulkhead and also the rear upper body from the lower body (ie the seal where if you removed the roof you'd be left with a ute); they all leak like a sieve and should be sealed with a good quality sealant.
cheers Gerald

[Sinti]

Step by step pic Door repair tut

Guide to Defender Door Repair | Repair My Landrover (http://www.repairmylandrover.co.uk/defender-repairguides/guide-to-defender-door-repair-internal-frame)

http://www.repairmylandrover.co.uk/defender-repairguides/guide-to-defender-door-repair-internal-frame

Have to do mine for a RWC to flog the beast
There are some other well made tuts on that site

[Wheely]

Hey guys,


I have started stripping down Wheely (which had been parked for 5 years under the rain of the tropical rains of the Ghana eastern side) - and to my surprise the internal part of the doors still look in perfect condition - not like 22 years old!


I'd like to keep it that way for some other years to come - what do you recommend me to do?


1- I have read in some threads that people when restoring doors they put some seam sealing between the alu part and the steel part - where do you actually put the seam seal? shall I live on the original paint or remove it and epoxy prime it, then apply a new 2k PU paint?
141116141117
your thoughts and ideas are welcome :)

[Didge]

Sell them to me for a song!
No? - Ok, get them hot dipped galvanized.