Door bottom repair - advice needed

[Oldmogman]

Could anyone advise on the best way to repair minor rust in the very bottom of the door skin?

Small rust bubbles have appeared in the narrow, straight edge at the very bottom of the door, while the seam on the inside where the door skin folds over the door frame has expanded (the only parts where my Waxoyling evidently didn't reach!). I've tried sanding, rust-killing and repainting, but the rust comes back.

(I have pictures showing this but the MMOC's wonderful new website doesn't seem to allow images to be attached.)

I know door bottom repair panels are available this seems rather excessive given that the rust is in a small area right at the lower edge. I'm not an expert but to my mind, the affected part of the inner seam would somehow need to be unfolded or cut out and replaced, and a small fillet of metal let into the outer edge.

I plan to have the work done by a bodyshop but I need to ensure the repair is done correctly, so the rust does not come back after repainting.
(I'd be interested to hear of any Minor specialists in the Bucks/Berks/Oxon area able to do this sort of work.)

Thanks all

[jagnut66]

Hi,
Take a look at this topic, he repaired the bottom of his doors (and the pictures are still present!!! --- the one that got away ).
Best wishes,
Mike.

viewtopic.php?f=28&t=54234

[mogbob]

Oldmogman
Whilst appreciating that it appears " slightly excessive " using a full length repair panel for a " small area " , think about the maths.
The repair panel from say ESM would be £17.95 plus VAT £3.59 = £21.54.

The bottom outer skin of the door needs to be cut out and removed.
The main frame of the door base needs to be de rusted ,inspected , maybe repaired with patches if it's bad. It should be given an anti rust treatment and at the very least given some paint ... primer and top coat , if you want a top notch job that will last.
The door skin lower edge , now exposed , needs sanding down , say a 1" strip . It then needs to be joddled inwards so that any moisture doesn't " sit " on a ledge and start rusting. A blast with weld thru primer on the joddled edge and any exposed metal is required.
The repair panel needs to be cut down to size , sanded to bare metal . sprayed with weld thru primers and welded to the existing outer door skin. The flanges , bottom and two side need to be bent over and the joins at the corners filled with tack welds. A light skim of filler over the join ( exterior of the car ) and then painting.

That's quite a lot of Bodyshop time. Rate per hour say £50 + / - ( more likely + ). How long for a fabricator to make a repair panel from scratch , out of a sheet of metal ? ...certainly more than 1/2 hour !! It's a no brainer for a garage .From a strength point of view using a repair panel for the full length, width wise , will be the best option.
Rust will always resurface until you can expose and treat both sides of the door frame base. New metal / repair panels need proper preparation as well. As you have found out a quick fix doesn't always work out well.

Although I've only used him for second hand parts , you could try Minor Parts of Oxford ( Richard Plant ... nice guy, genuine). Website http://www.minorpartsofoxford.co.uk Phone 01993 830349 Mob 07759 810336 email rgplant@minorpartsofoxford. Good standard of
bodywork repair witnessed when I visited the premises.
Good luck with it.
Bob

[Budgie]

I had my right hand door bottom of my tourer done about 18 months ago with a bottom door repair panel .Although it was almost rusted all the way through , it was only a maximum two inches from the very bottom and some 6 inches long but seeing as what's going on down there in respect to folds of steel plus I didn't want the rust to come back any time soon I opted for the repair panel .It cost me all in for a very professional job, blended to the existing paint and lacquered ....£250 but money well spent in my eyes.

[Mark Wilson]

and the pictures are still present!!! --- the one that got away .

If you PM Cam with details of posts which you think are particularly important he can ask the web people to give them priority. He very helpfully got the images put back in the "Thread sizes" sticky and NeilMG's and Taupe's Traveller resto threads after I pointed out that I thought these were of particular value (probably mentioned to him by many others as well!).

Mark

[jagnut66]

Hi Mark,
I believe I mentioned Taupes thread to him as well.
I know Cam is doing his best and I am aware of his offer to try and get some thread images re-instated, it's our new site provider that I think is letting the side down, something which I have also mentioned.
Best wishes,
Mike.

[Oldmogman]

Thanks guys

By slightly excessive I meant having to cut the entire bottom skin off an otherwise perfect door, not that the cost of a panel was an issue. However, I take your point about cutting down a repair section to suit the metal that does need replacing.

I'll look into Minor Spares of Oxford. In the meantime, I wonder if there are any classic bodywork specialists closer to me in Maidenhead, Berks, that anyone could recommend?