I have two Cracks on the driver side door that i have filled and
sealed. But i have noticed some rust on the bottom of my door.
it appears to be bubbly surface rust,but i am curious....door crack
rust at the bottom....hhhmmmm......sssooooo.... wire wheel,acid
treatment,fiberglass and paint.....or take the door panel out and look inside....i need help from a body person who can give me
a little insight...thanks.....dave....oh, the rust is on the inside
of the door........

 

Hey Dave,

I was hoping someone else would have jumped in here by now, but since that doesn't seem to be the case, lets see if I can help you any.

What year truck and where exactly are the cracks you've already fixed?

Do you know what the original cracks are from?

Bubbles means that most likely a larger area than seen is infected with rust.

If the outer door is in good shape and there is rust at the bottom of the door, especially since you said that it's on the inside, this leads me to believe that the water is possibly coming in from the window seals.

You definately need to take the panel off and see if you can find out where the weather is coming from. If it's the previous repair, depending on the year of your truck, you might be better off trying to find a door at a junk yard. Run some water over the window and outer door with the inner panel off and see if you can find where it's leaking from.

The repair, usually there's a pretty tough inner coating on the inner door. Without seeing the door, I would imagine that the rust is feeding up from the drain holes. The best fix would be to sandblast, treat with Ospho, primer and paint.

If you could post some photo's of the door in your photo gallery, we could get a better idea of what the proper fix is based on the area needing repair.

Hope this helps.

 

what i have is a 2001 F-150, 4 door,open from the inside. the door crack is right where the driver side door meets the rear door.
there is a lever on the crew door that meets the front driver door.
it was there when i bought it. i wire wheeled it, alittle bondo,primer,paint. the rust is at the bottom inside of the front
drivers side door. i didnt notice it when i bought it. i guess when
i was fixing the crack i looked the door over closer than before......
thats my bust for not taking my time at the dealer....anyway.
it was a bubble,approx 1 1/2 inch long,by 1/4 wide. when i tapped
it a bit with the ol stanley flat blade i about crapped. it isnt though
and though,but then again i didnt get to aggressive with it either.
i had two thoughts...one, they use boat loads of salt brine here
in iowa,during the winter ,maybe a scratch that oxidized,or water
getting in thought the crack before i fixed it. in any event i am not sure what to do with it,it is right at the bottom fold of the door. i
am almost tempted to take to a pro at a body shop......might be worth the money rather than me ruining the door......trying to fix it
i will check the windows in the mean time.....thanks again.....dave

 

Hey Dave -

Being a 2001, why wouldn't it be covered under the dealers bumper-to-bumper warranty??

It may take a bit of a fight and a few letters to Ford, but I would think that they should fix it.

Any ideas what the cracks were from?

 

dont you ever sleep.....my god woman.......no i dont,apparently
door cracks are common in the newer F-150.i have read many
posts here about them. as far as the warrenty goes i bought the
the truck with 46,000miles on it so thats a mute point.i have
an extended warranty that i bought, but the doors are not covered.....i am not that honked off....this is a great truck!!!!
we have a service maint road called old quass around here,its
good old iowa clay.......yep i went down it just to see if the
transaxle was it good shape. i know what has been said about the 4.6 , but i was impressed.....not the hotrod that the dodge
4.7 is,however the gearing , and the tranny is much better...
maybe i'll let her rust out like my '76 F-150 did.......all the same
if anyone has had a similar experiance with the doors i would like to here about it.......thanks carlene.......dave.......

 

Yeah, I get 4 to 6 hours a night whether I need it or not.