November 5, 2011I was washing my old 02 the other day and noticed on the bottom of both the front doors paint bubbling. Looked inside and behind the weather stipping a ton of rust. Whats the best way to repair and fix this so it doesn`t happen again?
Forums : Super Duty : My 02 Has Front Door Rust, HELP!! (1170 Views)
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March 12, 2012My `03 has the same problem despite the repeated washing and waxing I have done since the truck was new.
I noticed it about 2 yrs ago on the inner door surface. I took it to a trusted body shop and they told me that the cheapest/easiest/best way to correct it was to get 2 new doors. They told me that the rust was between the layers of folded metal and was therefore inaccessable. I asked about cutting and patching new metal but they said it was more labor and therefore more $$ than replacing the whole door. They also asked me if the car was still under waranty (it was not), because in their opinion, this is a ford defect.
In the short term, I have used a grinder on the inner face of the doors and then rustoleum spray paint. It seems to have slowed the rust on the inner surface of the door but I see the bubbles under the paint getting bigger. Unfortunately, I also have bubbles forming under the paint above the rear wheel wells. I am very disappointed in the paint and metal quality of this truck.
March 13, 2012once it starts there, the only way to stop it is to replace the door.