Rust lines on inside bottom on doors.

About 2 months ago I noticed some rust lines on the inside of my doors, almost near the bottom. It's about 1/2 inch from the inside bottom of the door, where there's a seam as the door sheet metal is folded over. On one door, the rust line is almost the length of the door, and on other doors, it's here-and-there, but always right on that seam.

The dealership told me the 5 year corrosion protection doesn't apply yet, because there's no actual perforation. They also said they've seen this before, but the rust hasn't penetrated to the "outside of the door" in the cases they've seen.

Any comments or experience with this? AND, suggestions on what I should do next? Seems like I should get this taken care of sooner than later, before it gets worse.

 

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Thanks, that's kinda what I guessed the answer would be.

Has anyone else noticed this on late-model Explorers? Trying to figure out if I'm in the minority.

 

I have seen that type of rust on beat-up late model POLICE Explorers. They rust there when run through a lot of salt on the highways, or water, off-road.

 

I ground the bottom inside lip of my doors off, cut bigger drain holes into the bottom and then rewelded sheet metal onto the bottoms to give it back its structural integrity.

The trouble with the current door design is that as dust, mud, gravel and water fall througyh the window seals, they sit on the bottom of the doors and cant drain out. Then once it gets wet it stays wet for a long time and rusts through.

 

I've also got the door bottom rust issue. Is there anything that I can do to stop/slow this down, short of cutting it out and welding on some new metal? Some of the paint on the inside bottom of my door has started to bubble a bit. Is this something I could sand down and then put something like POR-15 on it? (I think that's the stuff). WOuld that help? Any ideas are welcome!

TIA

 

I'm having the same issue. All 4 doors and the trunk have rust on the inside and its bubbling up. A product of my Ex spending most of its life in the salt-infested roads of Wisconsin and New York. I tried some naval jelly today to at least neutralize the rust a little bit but I think its a lost cause. I took it to a body shop and they told me that there's nothing I can do about it. He did say that I had probably 5 years before it'd show on the outside. By then, hopefully my Ex will be my 2nd vehicle ('06 Mustang GT here I come :-D) and I won't really care about the rust by then. But now, looking back, I wish I'd driven down south to find my Ex rather then buying one in Wisconsin. Oh well, shoulda coulda woulda as my dad says.

 

mine has done that as well, i had my painter sand it down good with a wire wheel and repaint. should be enough, in both of our opinions.

 

How bad was yours rusting Expo? Was it bubbling? And what did he charge you for all that? Thanks..

This might be a dumb idea, but would it be possible to get the inside of the doors line-x'd or something like that??

 

I have the same rust problem... scared me the first time I saw it. Expo's plan is a good one - just hit it up w/ some rustoleum primer first.

 

Hey expo5.0 are your dog legs going yet, after this past winter mine are starting to look horrible

also what painter do you use in the area

Ryan

 

he didn't really charge me because i was doing so much other stuff at the same time.

if you have a wire wheel you could do it yourself with a rattle can paint job (which is plenty nice enough for inside there where no one sees it for less than $50)

My dog legs are not going, nothing is going.

the painter i use is the chapter president over at ftw, dont' think your a member yet, but you shoudl come hang out with us at the next meet.

here is a picture of his work so far on my truck