Started my door rust repair...now I have questions

blueovalnotch65 · Aug 29, 2011

Hey guys, I started repairing the rust in the lower corners of my doors. I purchased the replacement panel and started to cut out the major cancer. I removed all of it from the outer skin but there is still some rust inside. Ill post some pictures and let me know what u guys think.

I did a search both in google and in here but wasn't able to find a thread on how to actually do it, everything was just explaining why and different options.

Im also going to post a picture of the left rear quarter panel/rocker where i have a decent amount of rust, I would appreciate suggestions for it too. Thanks.
View attachment 175379

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rusty428cj · Aug 29, 2011

That's why I replace with new doors because you can't clean up all the rust inside the door or match the grain on the interior side of the door.

69SlowResto · Aug 29, 2011

+1 with Rusty. I just didn't have the confidence that I could get rid of it all with a skin.

blueovalnotch65 · Aug 30, 2011

I ended up buying some POR-15 to put inside the doors. After reading multiple threads about the stuff, I feel pretty comfortable that it will fix any other surface issues inside the door.
Now I have cut my replacement pieces and hope it all comes out alright.
As I was cleaning away the rusted area on the quarter panel, I found a ton of body filler. I knew this thing had been in a wreck at some point in its life, but didnt know they completely re-shaped the quarters. Never fails to find more issues when trying to do a budge resto.

331efiblue66 · Aug 31, 2011

I found out early on that there is no such thing as a budget resto and still do it right. To do it right, you have to throw out the budget and just do it. I have been waiting 28 yrs to own one of these cars, and I only want to build it one time.
Judging by the amount of rust on the outside of that wheelhouse, to do it right, you really need to take that whole quarter off and replace in order to address those rust issues.

rusty428cj · Aug 31, 2011

Por 15 is very popular with the hobbyist but I don't know of any restoration shop that would use it.

lauras70mach1 · Aug 31, 2011

POR15 = body man in a can

blueovalnotch65 · Aug 31, 2011

331efiblue66 said:
Judging by the amount of rust on the outside of that wheelhouse, to do it right, you really need to take that whole quarter off and replace in order to address those rust issues.

I was looking at quarter panels and quarter skins.... What are the differences? Which is preferred? Ease of install?

NasaGT · Aug 31, 2011

I would re-skin the whole door so that you can cleanup the inside. That's what I did on mine. Before:

After:

Another option would be to patch your door skin, then remove it from the shell to cleanup the inside of the shell. Its pretty hard to take a skin off without damaging it, can be done though.

All of the above is time consuming. If you're trying to save money like me then it makes sense. Buying a door is the quickest path, and probable cheaper if you're paying someone to do it.

Started my door rust repair...now I have questions

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