Ideas on fixing rusted out holes?

SLiM · #1 (**permalink**) 10-31-2009, 09:53 AM

Hey everyone, I have some rusted out holes in both rear doors and I want to fix it, but I don't have a welder and I don't know how to work with body filler and all that plus I want to do it right with some sheet metal, any body have an idea on how I could fix them with out a welder and body filler? I thought about using sheet metal screws with an epoxy, thats the only thing I could think of? If anyone has a way to do it with out a welder or body filler please let me know, I just want to stop it before it gets any worse, so any advice would be great, Thanks in advance.

54cj3b · #2 (**permalink**) 10-31-2009, 08:07 PM

new doors

TerryMason · #3 (**permalink**) 11-01-2009, 12:42 AM

I don't think there is any way to "do it right" without a welder. Nothing will put the metal back except welding in some new metal.

Now, if you're like me, doing it "okay" is good enough

To keep things from getting any worse, you're going to have to remove all the rust, by sanding or grinding it down. This will likely make the hole larger in the process. Once the rust is completely gone you'll want to paint this bare metal with an anti-rust paint - I recommend POR 15.

So, you've got a nicely painted hole.. If you are set on screwing some metal in, I'd suggest you lay a piece of metal over the hole on theinside - meaning that the piece of metal is on the inside of your door, and you can see the rusted metal from the outside. You could then put some body filler in the hole and level it out some - it would look alot better.

Body filler is very easy to work with. If you can spackle a hole in your wall, or work with play-do, you'll be fine with this stuff.

SLiM · #4 (**permalink**) 11-11-2009, 12:12 PM

Well I just realized its not the door its right under the door so I was thinking about using an epoxy, I heard there is an epoxy out that when dried it turns into almost metal, plus I was gonna rivet it also, Im eventually gonna have the jeep painted a flat black also. I just dont want to spend alot on the paint because I take it off roading and its gonna get scratched up If I fix the two holes under bother rear doors ther body will be perfect. Any idea on what I should pay to get done I dont want to get ****ed and pay way more then I should of, I wish there was a way I could do it myself. any help would be great, Thanks bro.