Just thought I would share some pictures of the rust repair that I did over the last week or so on my 2003 F350. If the truck were a few years newer or a few thousand miles younger I might have been more meticulous with the repairs. For a rig with almost 200,000 miles this should help it survive until the engine goes....if you are a real paint or body person please leave suggestions on ways to have better accomplished this task since I really just winged it and it might be nice to others who are thinking of doing something similiar.

This is what it looked like under the rubber piece (I started grinding off some of the rust prior to these pictures):




I gave it a few coats of "rust to metal" stuff to attempt to slow the rust formation:



Here it is with some paint and then the rubber cleaned and installed:

 

Looks pretty good to me! Can't tell with your door gasket installed.

I would have put some more prep into it, but I understand where your coming from on the too old to care part.

 

The photo right above that one was taken seconds before I put the rubber back on.

We'll see how long it lasts. All it cost was a few cans of paint and a few hours time....

 

I would of took a wire wheel and really cleaned it up and sprayed etch primer on it before painting. Just to let you know the rubber that you put back on it is what causes the doors to rust out right there.

 

Not to hijack. But is their something else you can use as a fix or just take
The rubber piece out I always notice mine if filled up with crap

 

Came out great.

What tool did you use to make the metal look so shiny? Some of my door lip is pretty much gone. I wire wheeled the doors on my last truck and it came out ok, just wonderin if you were using anything different because it looks really good.

 

My passenger door is a little crusty like that, driver's side door looks fine. Although my driver's side rocker panel is scratched and scuffed like crazy.

Josh

 

https://www.google.com/search?q=flap...ml%3B580%3B580

I used a wire wheel to get to the rest of it since the flap disk isn't to good for getting around cracks.

Thad

 

Just take it out. All it does is keep dust from going to the door weather strip. It really doesnt do anything but causes problems.

 

Put some oil in the door panel, so it seeps down into the seam and prevents the rust from getting worse.
I use this 40w marine oil cause it doesn't smell, but apparently wd40 is awesome. Hydraulic oil also apparently a good choice.

Been doing this on our vehicles, the oily film causes a bit of dust to stick, but definately keeps rust away.

 

Fluid Film is even better.

 

Fluid film is very good, but it is not good at creeping.
WD 40 is very good if not the best at creeping in seams and folds.

Fluid film is really awesome, but a nice thin oil will soak through the entire seam. When I do my door, I pour it in the 1 grommet hole, and the next day the oily film is visible along the entire length of the seam, That is what you want to see.