Rear Door Questions.

Hey all!

I am working on getting this silly rear door back to fully working again but I am having many troubles I think the main issue stems from the huge rust hole in the door handle carrier.

Now the door handle has fallen off again we need this sorted.

To those that have purchased new rear handles, what was fitting like? also how is the best way to sort the rust? Remove and re-weld new metal on and drill the relevant size hole? are there better solutions that don't include a new rear door

Picking up new rear glass this weekend so being able to sort the handle at the same time would be ideal

Thank you!

Have you a picture??

Kev

Badger688 said:

Have you a picture??

Kev

Click to expand...

Don't have any right now, could always grab some after work later though

Pictures abound:


You can see the spring replacement clearly did not work for very long...
Then the rust hole big enough for the nut to go through:

Tis' falling to bits and needs replacement

1. If the handle is in one piece, then you treat the hole to stop the rust and a big washer (handmade if not big enough) will be glued (metalepoxy) to keep the handle. The washer is to be glued when you mount the handle, it will be perfectly positioned.
2. If the handle has broken studs, glue them first and then go to step 1.

The Pilgrim said:

1. If the handle is in one piece, then you treat the hole to stop the rust and a big washer (handmade if not big enough) will be glued (metalepoxy) to keep the handle. The washer is to be glued when you mount the handle, it will be perfectly positioned.
2. If the handle has broken studs, glue them first and then go to step 1.

Click to expand...

I presume it is 100% worth treating the rust hole with some sandpaper and paint? before I put it all back together?

There is a spray with a compound which integrates snd stabilizes rust. First a mechanical cleaninig as you say, some degreaser and this ruststop. It becomes black after cure. If I find it, I put a picture.

This is it. I was very satisfied with it.

And you do not need to clean to bare metal; it reacts to rust.

Appreciate the recommendation, I will have to find something similar in the UK!

You'll find for sure, it is not unique. I used it at the lowest zone of doors, where rust starts but is hard to cure.
Good luck!

xDParis64 said:

Hey all!

I am working on getting this silly rear door back to fully working again but I am having many troubles I think the main issue stems from the huge rust hole in the door handle carrier.

Now the door handle has fallen off again we need this sorted.

To those that have purchased new rear handles, what was fitting like? also how is the best way to sort the rust? Remove and re-weld new metal on and drill the relevant size hole? are there better solutions that don't include a new rear door

Picking up new rear glass this weekend so being able to sort the handle at the same time would be ideal

Thank you!

Click to expand...

You could always buy my brilliant 2003 TD4. New Forest area

mudinuri said:

You could always buy my brilliant 2003 TD4. New Forest area

Click to expand...

Don't tempt me!!! I really don't need another, have bought 3 already