I investigated the offside passenger door's remote lock today - it hasn't been unlocking for a couple of weeks now.

To get the door lock out you have to take out the upper door frame and glass.

Doing this I discovered that my door frame is rather rusty - not completely shot but very rusty at points.

Now, at £150 each I'm not in a rush to buy a new and I suspect this is a known problem so a second hand/breaker one will probably have the same issues so does anyone know the best way to patch up this rust?

I'm thinking Hammerite - its not like it'll be on show and there is a lot of rust.

Are there any other (better) suggestions to fix this?

Cheers

150 for a door? is that for a Disco?

I bought 4 complete doors (window regulator, windows, etc..all in) for my 200tdi, same colour, in perfect condition, off someone that was breaking one on ebay... 20quid each door.

I did the door locks and had the same problem, took the fram off nd it was a bit rusty at the bottom. Didn't do anything at the time, but hammerite or smoothrite would do the trick. You could get the satin black smoothrite in a spray an and do the whole frame even. Might have a go myself!

I bought the satin black smoothrite - just over £10 from Homebase.

I took the door frame out and had a whole new look at the problem. As ever it was worse than I'd hoped...
The quarter light is held in place by a horizontal section bolted to the main frame.
The design of this section means that water collects in it and, unsurprisingly, it rusts - badly.
So badly that one end had completely rusted away - meaning the glass was only supported by one end and luck!
I took a piece of metal (actually a piece that had not rusted but was not attached anymore), hammered it into an L shape and bolted it back into place - it made a ledge that the glass won't be able to fall through.
I then sprayed the rusty bits with 3 layers of smoothrite left it to fully dry overnight and then put it all back together.
Hopefully that'll all work!

Anyone using smoothrite should be careful to leave the paint in the warm for a couple of hours first use - otherwise it doesn't spray correctly!

I don't think I'd paint the whole frame with this stuff - I think I'd rather source a cheaper replacement frame - especially if I could get one for £20!

Actually, does anyone know of a part number for that cross member?
(Its not even mentioned on a certain piece of software )