Iron Oxide come from HELL, I SWEAR IT!

[Edweird]

And so it begins...

I broke out the micro-grinder and started with the worst patch I know. The front, inside, bottom of the passenger door. The photographs show how it was and what I've done thus far.

Large view of majority of rust

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That's most of it. There was also an area the had been covered with filler to the left. The previous owner had obviously done a little work to cover up rust.

Close up of worst area

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This is the worst bit.

The clean up has begun

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After spending a few hours with the micro-grinder and a tiny little file-bit-thing I've done this. I'm going to prime it to protect it once I'm done, then get some colour matched paint.

When it comes to filling the big hole, I've got some fibreglass sheet 'stuff' that you cover in a hardener paste 'stuff', which you shape and stick to the bodywork, then paint over. What about the smaller holes? Will fibreglass paste and filler be enough? We're talking from cotton buds up to half a fist, roughly...

Also, how do you get the window winder handle off? 0.o

[ScottieJ]

there is a little clip behind it, you can just see it if you push the rubber seal back a bit, use a smal screwdriver or you cna get a bit of rag and sort of wrap it around in the gap and it should push the clip off, it's kinda hard to explain how to do it though

[dominic]

Ed, as Scottie says, its quite easy to get the clip off to get the winder off.

As for the tin worm to the door, im sure you get away with using any type of patch up,either metal plate, mesh n filler. But if you can, get hold of spare doors.

Dom

[Edweird]

Alright, thanks guys. I had a look in the Haynes and I see what you're talking about with the rag. Cheers.

I have been considering riveting in a plate. I'll have to get a look inside first.

[Henry]

Get new doors mate.

You can get some tidy doors for little money, i have an immaculate set hear of my old one that i am about to make into half doors....


Then spend our time spraying them up and swapping the locks. All the doors are a universal fit too btw.

[Edweird]

I had considered new doors but I have next to no money to do the work. I'm using stuff my Stepdad has lying around the garage, along with maybe the cost of a tin of areosol primer.

The probelm with me getting new doors is you've got to buy the doors, then get the car colour matched, then the doors painted and then a new sticker made for the door. The cost just adds up.

[Henry]

http://www.shropshire-suzuki.co.uk/foru ... 11&t=12315


Get the stickers off you hairdresser!

[Edweird]

I've been mulling it over, and, as day by day more rust appears, new doors are looking more and more likely to be a far better option.

Henry, how much do you want for those doors? Could I give you my old ones as a part exchange, (e.g. their scrap value or something)? You could cut those up instead of the minters.