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wire brush,rust convert, kill rust and leave it...I would not consider it a major concern...good actually for applying rust convertor for the door top and keeping an eye on overall condition.My door tops are the same..just spray fish oil down there..seems to clean it out and control any further rust.
It is a bit tricky because it's so close to the aluminum. I have done it with a mig. It looks like the type of hole where you don't know where it will end when you start cutting it out.
The good thing about series 3 vehicles is apparent parts availability. I think I would rust converter it, fibreglass it (or just bog it) and wait until a better door came along, such as on ebay. They do come up. Then epoxy enamel the door to match the existing colour.
The hole won't stop you enjoying the car, especially on the beach.
I think that the water is coming in through the window channels. Just ordered new ones. I guess I will rust convert it, zinc it and leave it open until the new channels are in. Then I might just go fiber glass it or pick up on DarrenR's suggestion from above with the square from the back.
I'd weld it, but I don't want to take the door off at the moment.
But if you were to try and think of a part that is hard to get, one of the first choices would be the side rear door on a wagon!Quote:
Originally Posted by rar110
John