Cancer creeping up under door hinge!!!!!!!!!

[9 Deuce GT]

I don't see a forum for body work, so hopefully this is the correct forum for rust damage.

I bought my car in 1997 and have kept meticulous care of it. Any little problem with it was taken care of professionally. I have kept up with every little problem it has had. But what I saw yesterday scared the **** out of me. I was looking at the door sill area. I have noticed a tiny little bit of surface rust near where the body overlaps and is welded together by the door light button. I leaned in to see it a little more up close. I just happened to look past this area and in between where the upper door hinge is, and damn near passed out. There is a good amout of rust just under the hinge. I initially thought it might be all the way through the panel, but upon closer inspection today, I see it is not all the way through. I know the door needs to come off for a better inspection, but how do I keep this from rusting anymore? Is it fixable?

 

[qcrun98]

What I have always done with rust is just sand it all the way down to the metal and primer over the spot. Make sure that all of the rust is gone thought it will still spread under the paint if you paint over it. By the way nice a@@ mustang.

 

[qcrun98]

Sorry also the best tool that I have found for small spaces like that one to remove the rust is the Dremel hand tool. Make sure if you use one that it is the electric one not the battery operated one.

 

[9 Deuce GT]

By the way nice a@@ mustang.

Thanks for the compliment. I appreciate it.

I guess I just am not ready to come to grips with the fact that these cars are in need of a restoration. I think I over reacted a bit, as the damage is no where near life threatening (up to this point), but I know it will eventually be a huge problem. There is no cure for the existing metal. Only cut and weld, which I am not ready for.

I plan to take off the fenders and doors this winter to really get a look at it. I am just a little unsure of the correct procedures. I do not think cutting these spots out and welding in new metal is feasible for me yet. I think I might take my chances with some sort of rust encapsulator, sealer, and primer/paint for now.

The worst part about it is the car is in a garage all year long. I only drive it on sunny days, and during winters it is tucked away. The car has litteraly only seen rain three times in my 9 1/2 years of ownership. I curse the kid I bought it from, as it suffered for 4 months in the Rochester, NY winter. (read=salt city) I whole heartedly believe the original owner never drove it in the winter, as the body is in too good a shape to reflect it's first 5 years in the salt. There would be major rust holes if it truly was a winter ride in all those years prior to my ownership. Most people would think that I am crazy to obsess over this issue. I hate it. But, I guess some of the nicest classic Mustang have had to endure total restorations at some point.

 

[TrophyHead]

I would use a rust encauplator like you said. You have to get to bare metal. Body filler sticks to it best. If it's not rotten through yet I would try to attack it quick. You could do it cheap and nobody will tell from in there.

You need to go to the a local paint autmotive store. Forget Bondo. See what kind of body fillers they have. I would look at two part epoxy fillers and tell the counter people excately what your doing. They know what's up.