Yes more rust, what do you expect? This rear door would be better off replaced. It has some panel issues other than rust… but I’ll have to fix it, because I have not been able to locate a replacement door.

First on the list… the door jamb area where the outer skin and the inner skin are very close together.

Cut it out, weld in a new patch.

The outer skin was stripped of all paint with 80 grit disks on my Makita polisher/grinder at low speed. Now to cut out the bad spots in the lower corners.

Corners cut out and the inside door structure treated with Picklex-20, then painted with Zero-Rust.

The corners of the cowl, hidden behind the fenders actually get wet on the inside every time the car is exposed to rain. There is a drain hole in the bottom of these corners, but it gets jammed up with leaves and stuff…. so of course, they are prone to rust. On this car, both sides have pinholes scattered throughout. Of course, consistent with the rest of the car, the drivers side is much worse and will need to be completely replaced. I cut the corner off of the Biscayne parts car, because it was in pretty good shape.  I was able to repair the passenger side just by zapping the pinholes.

Time to put some primer on the firewall, door jambs, and the dash… stuff easier done while the body is still on the rotisserie. I used PPG DPLF primer.