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Apr 26th, 2026 | | AD Chevy Trucks  Over 6,000 pictures Brad Allen has an awesome collection of Chevrolet factory pictures that he has set up from film strips. Check them out!
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| | | | Joined: May 2004 Posts: 204 Wrench Fetcher | | Wrench Fetcher Joined: May 2004 Posts: 204 | I have some rust on the lower inner doors. It has eaten through along the entire edge.
Should I:
1.cut it out and weld new metal back in
2.paint it with rust inhibitor (POR-15) and body fill it up and call it good? | | | | | | Anonymous Unregistered | | Anonymous Unregistered | If you have a welder then cutting it out and replacing it is the best way. If you do not have a welder then cutting it out and fiberglassing it may be an option if you do not have the means of doing a permanent repair. The fiberglass would be a temporary solution but would get you driving and provide a surface for your weatherstriping to seal against. POR is a PITA. Use Zero Rust instead especially for this applciation. | | | | | Joined: Oct 2001 Posts: 3,458 Extreme Gabster | | Extreme Gabster Joined: Oct 2001 Posts: 3,458 | The issue with doors and fiberglass is that you are generally going to make the problem come back unless you replace the rusty metal with new. Doors are made to have water draining down the inside and out the bottom, and since they rusted in AZ I would suspect that the drain holes plugged up at some point. The fiberglass will certainly not help this and will probably trap more moisture against the remaining good metal.
You ought to be able to find some good doors in AZ, or you could try to repair what you have.
Paint & Body Shop moderator
A lone amateur built the Ark. A large group of professionals built the Titanic. | | | | | Joined: May 2004 Posts: 204 Wrench Fetcher | | Wrench Fetcher Joined: May 2004 Posts: 204 | Ohh but my truck came from South Dakota. I think my door holes were plugged. I did cutout the rusted metal and I am welding in new metal. It wasn't that bad but it did run along the length of the door.
My next question is now with the new metal do I fill the gaps with body filler or do I use fiberglass? I was able to keep the metal to fit pretty closly with the form of the door. Also with the weld ground down it isn't too much to fill. But if I use body filler and moisture does ever get in the the door will it effect the body filler? | | | | | | Anonymous Unregistered | | Anonymous Unregistered | Use body filler then a good epoxy primer. Replacing the metal was the best way to go. | | | | | Joined: Aug 2005 Posts: 442 'Bolter | | 'Bolter Joined: Aug 2005 Posts: 442 | try Raybucks.com...dont know any Texas dealers, but raybucks has it, about 14 a quart, and low shipping costs. Mike | | | | | Joined: Oct 2001 Posts: 3,458 Extreme Gabster | | Extreme Gabster Joined: Oct 2001 Posts: 3,458 | Body filler will be affected by moisture. Worse, the metal behind it will rust.
Paint & Body Shop moderator
A lone amateur built the Ark. A large group of professionals built the Titanic. | | | | | Joined: Oct 2006 Posts: 339 Shop Shark | | Shop Shark Joined: Oct 2006 Posts: 339 | Actually rust is not much different than cancer
in a human being, once You get it, it more than likey will be back...but it sounds like You chose the best option, excluding buying different doors..
Primer is not waterproof, but paint is, so I
would spray paint on the inside of the door where You made the repair...it will help You buy time with
the rust problem....BB | | |
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