So, reading around here, this seems to be quite a common problem...I was wondering if anyone's ever hit their inner door rust spots with some kind of truck-bed liner, like Line-X or Rhino Lining.
This stems from an idea I had of going around the fender and down to the rocker panels with Rhino Lining to prevent scratches and bumps. Looking at the rust, I thought if I did that, maybe I should just hit the bottom of the door as well. Plus, it would look pretty badass ATMO...a white car with some black trim on the bottom
Then maybe I could ditch the silver hubcaps and finally put those damn NASCAR decals on my car (only partially joking).
What do I know? LOL! I was going to order some for the Ricer drivers front door but ended up replacing the entire door so no need for it now. There were rust stains on the plastic door sill cover/skirt from the original door as shown in the picture below. The rust was coming from the crimped metal bottom of the door. I haven't taken a good look at the original door yet. The moisture shield on the inside of the door was completely intact along with all the weatherstripping etc. I suspect a clogged door water drain for this. No rust like that on the Passenger Front door or either of the rear doors.
I've cleaned up the doors on my Intrepid, they were pretty bad. I ended up cleaning the rust off with a wire brush, cleaning it with solvent, taping it and then painting on a coat of POR-15. The problem with this rust spot is that the rust is actually coming from the inside of the door or crimp, it's not surface rust. A better way of doing it would be to get inside of the door and apply the POR-15 in there along with the outside too and hope that you sealed it all. And even then, there's no guaranty that it would 100% stop it. The only for sure way to do it is to either replace the door with a new one or have the lower lip pealed back, blasted/cleaned up, re-sealed and re-assembled, very expensive.
One question about the door rust...I've read several sources saying that rust like mine is indicative of a plugged drain hole in the bottom of the door. My concern about that is about the timing of it all. All 4 of my doors started to rust right around the same time, shortly after winter. If it truly was a plugged drain hole in each of the doors, wouldn't the doors have started rusting at different times?
In short, hit the rust before it get's bad. Grind it spotless, epoxy primer it, lay the rockguard/rhino liner etc. then paint over if you wish. Won't have to worry about it again if you cleaned the rust right.
I was at Autozone today, chatting with an old friend from high school who worked there. He pointed me towards some Rust-Oleum rust remover, and suggested the quart of Herculiner for doing what I had described to him...he's actually done a similar thing to his car, and had good results.
Now...does anyone have a DODGE stencil, or something die-cut that I can paint onto the car using the bedliner?