Passenger Rear Door Rust

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.

Rust!

Cut it out, weld in a new patch.

Rust!

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.

Rust!

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

Rust!