Hello,

I have a 98 XJ that is in pretty good condition apart from the rusting area (pictures below). A couple years ago we tried sanding and cleaning the area, and patched it with a metal bodyfiller and sprayed bedliner over it, however this spring the rust started showing up again, and it looks like it has advanced further and has rusted through the door. I'm trying to figure what is best to do, ideally without having to purchase a new door, and think the best route is to cut it out further and patch with new sheet metal. Because it has rusted out the corner though, I'm unsure of the exact way to go about this, would anyone have any suggestions? Thanks a lot!
Exterior
Interior

 

Sometimes its easier just to replace the door. But if thats not what you want, you are going to have to sand it down again and start over.

 

Sanding it down and using body filler is a waste of time. It buys you a couple of years, maybe, as you found out. It's not because you didn't do it right, it's because that's the nature of the beast.

If you want a permanent repair, there is only one solution: Cut out the rot and weld in new metal.

 

If you do catch rust early and use some rust converter it'll usually work. Just make sure it's very dry first and knock the loose stuff off. Sand it well and clean with a pre paint cleaner. Spray a few coats of converter and seal with epoxy primer before paint or filler. I prefer to use the fiberglass resin as it doesn't absorb water. Of coarse I prefer to cut out and replace whenever possible. I will sometimes just seal it well to buy some extra time.

 

Yeah, sometimes ya gotta do whatcha gotta do. I have been known to use aluminum roof flashing to patch a rust hole to pass inspection.

 

That is an easy fix. Go to the salvage yard with a cordless reciprocating saw and hack off the corner of a door. Cut a few inches more than you need so you will have extra to work with. then cut out your rusted door section and weld new door section in. or just take the entire door and cut it at home. some yards only charge $50 for a door

A replacement door is easier than that but thats assuming you can find the exact door you need. year, number of doors, color, power options ect

 

Thanks TrailerTrash, hadn't though of that before, will see if the local pick n pull has any jeeps...otherwise I just get some new metal and weld it in place