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Old 10-03-2011, 03:00 PM
Stretch's Avatar
Stretch Stretch is offline
...like a shield of steel
 
Join Date: Sep 2009
Location: Somewhere in the Netherlands
Posts: 14,461
Remove the door handle.

With angle grinder and wire brush attachment remove the rust.

De-grease the area with POR15 Marine clean.

Kill the rust with POR-15 Metal Ready / KBS rust blast.

Apply 2 coats of POR-15 rust stopping paint

POR15, Inc. - Stop Rust Permanently - Repair Gas & Fuel Tanks

KBS Coatings - Paint Over Rust - Stop Rust Paint - Gas Tank Sealer - Gas Tank Liner

This will stop the rust and stop it from spreading any further. It is likely that you'll have to treat both sides of the door.

The only problem you have now is that you'll have a black patch on your door.

To get it back to the original colour you can use POR-15 self-etch primer (also available in an aerosol) and then normal products such as a high build primer and then your colour coat (code for this colour can be de-coded by the dealer and perhaps some of us here if you provide your VIN) and possibly a clear top coat depending on how your colour coat is made...

In short a lot of work to do it properly.

Please note I have no shares in POR-15! Honest!

I have tried their products as well as the KBS ones and I can't tell the difference between them.

Others recommend Eastwoods products

Auto Body Repair Tools Shop, Auto Body Supplies, Automotive & Classic Car Restoration - Eastwood

To date after buying loads of their stuff I have only had trouble with one of their products and to be fair I was using it incorrectly - so Eastwood's stuff also good.
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1992 W201 190E 1.8 171,000 km - Daily driver
1981 W123 300D ~ 100,000 miles / 160,000 km - project car stripped to the bone
1965 Land Rover Series 2a Station Wagon CIS recovery therapy!
1961 Volvo PV544 Bare metal rat rod-ish thing

I'm here to chat about cars and to help others - I'm not here "to always be right" like an internet warrior



Don't leave that there - I'll take it to bits!

Last edited by Stretch; 10-03-2011 at 03:01 PM. Reason: Spelling!
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