ford expedition doors rusty

R

richrd

what is the best way to fix this rust on a '01 Expedition? Or would I be better off looking for better (unrusted) doors? The rest of the vehicle is in good shape and I want to keep it.



thanks
Rich
 
That's a ton of work to fix right. Whole new skin that is glued on is the best repair and the only way I'd do it. The entire bottom of the door is bad once you get into it. If you fold the pinchweld back their isn't any good metal left. Just putting a patch along the bottom is a ton of work and usually only last a year or two before the welded seam starts to crust. (now if you tig it or gas weld the entire seam, planish, and epoxy your doing it right but whats your time worth)? Epoxy helps this but most of the time it's corrosion from the mig weld seam. If you can seal it inside and out then that helps but you will have hot spots that you can't get to.

Body shops around here would install a lower door patch, random stitch the butt weld and wipe all metal or fiberglass filler over to seal and go from there. Not my recommendation but I understand the cost from a bodyshop perspective.

If the vehicle is worth it I'd buy some new doors. Midwest junkyard doors are junk. Maybe the guys out west have good ones but shipping puts them at new prices.
 
I would consider blasting the bottoms, cleaning out the inside best you can and literally pouring epoxy inside the door. May not stop it entirely or fix it perfectly, but you may lengthen the life of your doors.

Reminds me, I need to do this to mine,but I have too many to-do's ahead of that :eek:
 
To add to what Marty said, a good way is with door laying on a stand, tape all the holes with tape mix up a quart of epoxy and add about 10% reducer, dump in door, tilt door so runs in all edges, then in about 4 hours do it again and I like to do it a third time after another 4 hours.
Un-tape one hole and drain left over epoxy into a painters paint and pour into the other door or strain and use on car.
 
Sand blast, hand sand and 700-1 as needed.
Not easy on some doors but just do best i can.
 
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