Rear Door Fix

border · May 6, 2020

Nearing the end of my Rebuild after just over 2 years

Anyway Cant really afford to spend much at the mo due to the Situation we are all in.
The Door is not to bad condition apart from one corner and a little bit in the middle, aint got a welder or as said cant really afford to pay to get it welded.
Just wondering if there is any way I could fix without welding. Any Ideas ?

kevstar · May 6, 2020

U or L shape metal & pop rivets or use chequer plate.

border · May 6, 2020

kevstar said:
U or L shape metal & pop rivets or use chequer plate.

Good Idea Mate, Ive got some Checker Plate too.

doriz · May 7, 2020

My rear door is in worse condition and its solid. The issue you will have is either riveting the internal door panel or pop riveting some checker plate. Get it rust cured and dig out the weak metal. If your glass isn't sealed the water will run down the internals and add to your issues.

Corfewoodsman · May 8, 2020

Hi,
I had the same problem and what I did was:
1. Attack all rust with an angle grinder leaving gaps and holes in place of rust.
2. Paint affected areas from exposed clean steel with Hammerite. I gave it two coats.
I then used a left over galvanised plate strap (available from builders merchants if you don't have one handy or a mate that has one). These have a 90 degree bend that fits with the corner of your door.
Because much of the bottom of the steel frame had been removed away from the corner, I was able to offer the plate strap to sound metal. The vertical portion slotted into the hollow box section side of the door while the horizontal engaged with the underside of the top of the bottom section. Of course I had to cut it to size, again with my trusty grinder.
3. Mark and drill holes that correspond with some of the holes in the plate strap, you'll be spoiled for choice!
4. Bolt the door frame to the plate strap, the heads of the bolts will not be a problem as they will be accommodated by the rubber door seal.
5. Paint everything in a colour close to your body colour. I used White Hammerite and blew it over with Rover Leyland White aerosol. Add the trim panel and away you go.

There are the gaps in the bottom of the door frame where the rot has been removed but these cannot be seen when it is closed and also provide useful access if you want to spray rust inhibitor into the steel box frame in the future.

Anyway, I wish you well in whatever you decide. It is very doable!
Good luck,
Graham

border · May 8, 2020

Corfewoodsman said:
Hi,
I had the same problem and what I did was:
1. Attack all rust with an angle grinder leaving gaps and holes in place of rust.
2. Paint affected areas from exposed clean steel with Hammerite. I gave it two coats.
I then used a left over galvanised plate strap (available from builders merchants if you don't have one handy or a mate that has one). These have a 90 degree bend that fits with the corner of your door.
Because much of the bottom of the steel frame had been removed away from the corner, I was able to offer the plate strap to sound metal. The vertical portion slotted into the hollow box section side of the door while the horizontal engaged with the underside of the top of the bottom section. Of course I had to cut it to size, again with my trusty grinder.
3. Mark and drill holes that correspond with some of the holes in the plate strap, you'll be spoiled for choice!
4. Bolt the door frame to the plate strap, the heads of the bolts will not be a problem as they will be accommodated by the rubber door seal.
5. Paint everything in a colour close to your body colour. I used White Hammerite and blew it over with Rover Leyland White aerosol. Add the trim panel and away you go.

There are the gaps in the bottom of the door frame where the rot has been removed but these cannot be seen when it is closed and also provide useful access if you want to spray rust inhibitor into the steel box frame in the future.

Anyway, I wish you well in whatever you decide. It is very doable!
Good luck,
Graham

Thanks Mate gonna give it a go, not sure what you mean by plate strap but will cut all the bad bits out then take it from there.

jamesmartin · May 8, 2020

border said:
Thanks Mate gonna give it a go, not sure what you mean by plate strap but will cut all the bad bits out then take it from there.

just paint it with a rust killer for the moment,then later buy a new door or get frame repaired properly ie new framing welded in

border · May 9, 2020

jamesmartin said:
just paint it with a rust killer for the moment,then later buy a new door or get frame repaired properly ie new framing welded in

Sounds about the easiest option for now James. Gonna have a go over the weekend,

TD5Tom · May 9, 2020

Fiberglass it. It will never go again and u can use fiberglass and if done properly you dont even no it's there.

Rear Door Fix

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