Rusted doors

[SuperSweptline69]

I'm sure all of you have came across this problem. What is the best way to repair my doors? They are rusted on the bottom I'm sure from years of rain water. I was thinking about cleaning up the best I could then fiberglassing in where it is rusted then maybe a coat of body filler over the fiberglass. You guys think this might work? I really see no way to weld it back up as the metal is to thin and rusted.

[wally426ci]

Maybe someone has doors you can use?

The rust will come back through the filler unless you use POR metal ready or Ospho to treat it first....

[SuperSweptline69]

Yeah that is why I ask, since it will come back. but I wasn't really sure since I would be using fiberglass. If you can make a bass boat out of it surely it will hold on a Dodge truck

[wally426ci]

Id say the fiberglass would retain its shape but id be afraid of the damage beneath it. Plus it may seperate from the metal after rusting.

[SuperSweptline69]

i thought about that also, but i really dont know what else to do. cant weld it, bondo will bubble after awhile and beside slamming the door will cause it to crack. so fiberglass might hold. maybe a layer of bondo 1st then glass. i donno

[DINODE]

I would sand down the metal as much as possible then treat all the metal with an encapsulator such as is sold by Eastwood. Then use fiberglass matt to get the basic shape and then use as little bondo as possible to smooth the finish. If done right this repair should last a long time.

[Jims68]

Is it just the outside that is rusted? OR is the inside rusted as well? I made new repair panels for my truck, and my truck was also rusted on the inside and I had to make all that new as well. Can be very time consuming. If you can't find good doors then you have to repair what you have.

Jim