fixing door rust!
Junior User
Joined: Dec 2014
Posts: 70
Likes: 0
From: Central Arkansas
Mine are rusty too. Stopped by the body shop yesterday in fact to ask about repair. I guess they're not interested in doing real repair work cuz he told me they wouldn't be able to fix mine just look for new or good used doors but I know this is a problem on all super duty and excursions plus the X rear doors are different from the trucks. I asked if he could reskin the door and build new structure on the frame of the inside to have material too bond the outer skin to and he said they don't do that. Guess I'll have to find a custom shop.
So I've just been letting it go.
What do you guys mean when you say it "pops?"
Mountain Pass
Joined: Feb 2017
Posts: 125
Likes: 10
From: Chicago
Thanks for the pics 1 Excursion camper! Looks great, can you walk us through what you did? Looks like it was cleaned with a wheel and then painted and coated with a rubberized coating? Do you remember what products you used?
Would it make sense to keep the weather stripping off after repair to keep moisture off area?
Would it make sense to keep the weather stripping off after repair to keep moisture off area?
Mountain Pass
Joined: Feb 2017
Posts: 125
Likes: 10
From: Chicago
I've had my EX for 2 years now and it was is great shape when I got it and I'd like to keep it for years to come.
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Cargo Master
Joined: Oct 2006
Posts: 2,097
Likes: 5
From: chicago northwest suburbs
I used a fiber wheel to remove all the rust on the outside lower edge of the door. Then I put a thick layer of POR15 down inside the bottom of the door and let it soak into any rust and crevices. I then brushed the lower out side lip where the rust was removed with POR15. After it cured I masked off the lower portion where the small weather strip (more like a guard to keep crud from inside the door jamb) runs and used some commercial grade undercoating. So all you see is a small bit of black undercoating at the lower lip. You can see that in the last 2 pictures.
Elder User
Joined: Jul 2016
Posts: 646
Likes: 4
From: Blue Springs, mo
Mine is pretty bad on a couple doors and if I wheeled it in sure I'd lose a substantial layer of metal. I think mine it's so bad in a couple areas that the door skin where it's wrapped under and over the inside of the door frame structure, it's basically just rust.
I know there are body shops that if need be can remove all the rust and fab new metal and weld it to the door structure then possibly replace the whole or lower part of the skin. That's real fabrication and some shops don't want to"waste"their time doing fab work. It can be done. It's not cheap but if finding rusty free doors is not an option what else do you do.
I know there are body shops that if need be can remove all the rust and fab new metal and weld it to the door structure then possibly replace the whole or lower part of the skin. That's real fabrication and some shops don't want to"waste"their time doing fab work. It can be done. It's not cheap but if finding rusty free doors is not an option what else do you do.
Fleet Mechanic
Joined: Mar 2004
Posts: 1,483
Likes: 1
From: SE PA
Thankfully, my doors are still good. I pulled all the door panels last winter and sprayed Fluid Film inside all. Hoping to avoid future issues...
There's a guy local to me with 3 Excursions. We know each other from a local body shop. I don;t know where he gets them...but he buys new doors to fix the rust issues...
There's a guy local to me with 3 Excursions. We know each other from a local body shop. I don;t know where he gets them...but he buys new doors to fix the rust issues...
Mountain Pass
Joined: Feb 2017
Posts: 125
Likes: 10
From: Chicago
If you call around you can find dealers and ford suppliers selling parts very cheap that they want off their shelves.
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Hotshot
Joined: May 2005
Posts: 13,484
Likes: 42
From: Stevens Point, WI
I use diesel waste oil as I have allot on hand and it is thicker.
I pull the door panel off and either use a brush and brush it around the inside of the lower door. Or if have it out and ready to go I will spray it in with my cheap Fleet Farm paint sprayer.
I have heard some use a pump up lawn/chemical sprayer. I haven't but I would like to give one a try sometime as they usually have that nice long wand sprayer that a guy could stick in places. I think it would work good for rockers and other closed in areas.
Mountain Pass
Joined: Feb 2016
Posts: 156
Likes: 1
From: North Carolina
Mine is pretty bad on a couple doors and if I wheeled it in sure I'd lose a substantial layer of metal. I think mine it's so bad in a couple areas that the door skin where it's wrapped under and over the inside of the door frame structure, it's basically just rust.
I know there are body shops that if need be can remove all the rust and fab new metal and weld it to the door structure then possibly replace the whole or lower part of the skin. That's real fabrication and some shops don't want to"waste"their time doing fab work. It can be done. It's not cheap but if finding rusty free doors is not an option what else do you do.
I know there are body shops that if need be can remove all the rust and fab new metal and weld it to the door structure then possibly replace the whole or lower part of the skin. That's real fabrication and some shops don't want to"waste"their time doing fab work. It can be done. It's not cheap but if finding rusty free doors is not an option what else do you do.
I've spent a lifetime in both environments, and that's why so many of you have a hard time finding a shop to get rid of your rust. That's also why there is a growing market for gimmicks like brush on rust stoppers.
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Cargo Master
Joined: Oct 2006
Posts: 2,097
Likes: 5
From: chicago northwest suburbs
I have a restoration business and we fabricate repair sections often. Regular body shops don't do this stuff because they don't have people who know how. Making parts and taking new parts out of boxes are worlds apart.
I've spent a lifetime in both environments, and that's why so many of you have a hard time finding a shop to get rid of your rust. That's also why there is a growing market for gimmicks like brush on rust stoppers.
I've spent a lifetime in both environments, and that's why so many of you have a hard time finding a shop to get rid of your rust. That's also why there is a growing market for gimmicks like brush on rust stoppers.
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