1979-1993 & 94 Conv [Subscribe to Daily Digest] |
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On my 1993 900S 16 valve, I had two rust holes forming in the visible portion of the inside of the door between the door liner and the rubber strip at the bottom. This weekend I took the door apart and treated the rust. Once I took the door apart, I noticed four areas of rust in the door.
1. I had to remove the door handles, the door liner, and the thin plastic water barrier behind the liner to get at all the rusted areas. The water was a PITA to get off until I started cutting the gooey black water seal with a knife rather than peeling it off. I had to move the bottom portion of the door seal and the most of the bottom rubber strip.
2. My rust appears to have orginated at the two drip holes punched into the sheet metal behind the plastic water shield. Because the holes are punched, the metal is rough and was inadequately sealed and painted from the factory. The areas around both holes were rusty, one had rusted enough to allow water to drip through the gooey black seal onto the rubber strip at the bottom of the door.
3. The dripping water pooled at the bottom of the door and under the rubber strip causing the rust holes at existing holes in the door where again the factory sealant and paint were thin or poor.
4. If you catch this rust early enough, it is quite treatable with POR-15. I recommend using the zinc phosphate treatment (metal-ready) under the POR-15 for better protection. I used fiberglass cloth over the treated holes and used the POR-15 on the cloth instead of bondo. I'm not a body repair expert (I hate body work) so don't take these as proper technique but for the small holes at the bottom of the door that are mostly hidden, this was good enough.
4. I wasn't sure exactly how to get the rubber strip at the bottom of the door back on so I used some 3/16 inch rivets from Lowes. I treated those holes with the POR-15 before putting the strip back on.
Any other tips or observations? I can post some 'before' pics if anyone wants to see them. I don't have too many 'after' pics since I was in a hurry to get it all back together.
posted by 140.185.5...
, Mon, 18 Aug 2008 19:50:35, Mon, 18 Aug 2008 16:40:45
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