Hello Landy Zone brain trust. I have more or less run out of ideas in trying to remove the window frame from the passenger's side door of my brother's 109 five door. I decided to repaint the door and wanted to remove the window frame so that I could get at the very top of the door but the long studs that go from the window frame down through pipes in the door are well and truly rusted in place. We had to use a Dremel tool to cut slots in the nuts so that we could open them up with a chisel and get then off the studs. After that no amount of pounding on the studs will get them to move. First we tried penetrating oil with not effect. I then heated the studs and bit of protruding pipe to red heat with a torch and we pounded on the studs while still hot but again no movement. Lastly I tried pouring motor oil on the hot studs with the idea the heat would thin the oil and let it run down into the pipes but this also did nothing. My last idea which I have not yet tried is to dribble muriatic acid (hydrochloric acid) onto the studs every day for a week to see if the rust in the pipes can be converted to iron chloride which is water soluble. I might then be able to flush it out with the pressure washer or hot water.
Anyone got any other ideas? This would seem to be a somewhat common problem with these doors. If I cannot get it off its not the end of the world as I can paint what is exposed.
Thanks for any suggestions.

Put old nuts on and keep hitting. As soon as you get movment hit them back and forth. Lots of heat on the stud.

rob1miles said:

Put old nuts on and keep hitting. As soon as you get movment hit them back and forth. Lots of heat on the stud.

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Cannot put old nuts back on as we have split them in half to get off. Don't think it would make a diffference if I was pounding on the studs with or without the nuts. Cannot use heat anymore as I have painted the exterior of the door. Thanks for the reply though.

The problem is that if the studs are that badly rusted in then the odds are the window frame has rotted though and that's how the water is getting down the studs. The job then is to get the glass out in one peice, and get the door tops off by any means without damaging the lower door. Then get new door tops and seals and really grease the studs. The best price / performance balance in my view is the galvanised door tops as these come in at around 50% more than the plain ones but will last many times longer. Fitting all the window seals / trim is a faff but it gives you the chance to waxoil it all.

No need to pain the door strip, it is galvanised. If the door top is still good just leave it as is. One day it may well surprise you and come free on its own.

tottot said:

No need to pain the door strip, it is galvanised. If the door top is still good just leave it as is. One day it may well surprise you and come free on its own.

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Yea, this is basically what I have done. The window frame looks fine, no visible rust. It's just that it would be nice to take the frame off and drive around that way, especially in the summer.

They are prone to being seized by rust, long term best option to replace altogether.