I bought my new to me cherokee because of the fact that the body is straight and solid and seems to be overall well cared for. There is a tinge of rust along the bottom of the door here, and it goes through to the inside of the door. I'm not sure of the best technique to remove this rust, any suggestions? If it was a fender rot hole or something like that I would patch it with glass filer and sand to shape. This is a bit different. What would you guys do?

`Rick

 

I had something like that. I ground down the rust and applied duplicolor truck bed coating from the bottom of the door guard down. I also took the the inside panel off to get at the bottom of the door inside. If you go this route, remember you have several drain holes you want to leave open. i feel the bed coating seals better and after I'm done with the jeep, it's going to scrap.

 

Rust is from the inside-out, only good repair is to re skin the door.

 

Pretty much what Turbo X_J said. My '00 is in pretty good shape but both my passenger side doors are rusting on the inside at the bottom and the paint is starting to bubble on the outside. To slow it down I POR 15'ed the inside. One day I will source some rust free doors from somewhere and with a little luck they will be black like my Jeep so it will just be a straight bolt on.

 

At the least it should be cleaned and dried and some rust reformer and epoxy primer or paint applied. That will keep it from getting worse. If getting a good door or welding is out of the question then there's no reason why glass mat and resin can't be used. Definitely do as others have said and remove the panel to access the inside bottom of the door and seal it up.