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[markrl]

Just discovered the very beginnings of the dreaded rust starting under the rear offside door weather seal under the window. The car is a 1998 Elite 3 litre manual 63k on the clock. Has anybody got any experience of tackling this successfully and would this be difficult/expensive for a body shop to carry out. I know a lot of places are not terrible keen on rust removal for fear you'll return a couple of months later with the rust back again. It’s only on one door and in one very small local place. Car is absolutely mint otherwise. Gentlemen I should be grateful for your advice as bodywork is not my forte.

[Auto Addict]

Can't help you with the rust, but it would be useful to others if you could post a picture, to give a idea how bad it is.

[STMO123]

They all seem to go in exactly the same places. Trouble is, I wouldn't mind betting it started inside the door and is just starting to show on the outside.

[JasonH]

I'd say your best bet would be to find a replacement door from a scrapyard.

Once the rust starts it's hard to stop (and expensive). Otherwise try to learn to live with it....

[Marks DTM Calib]

I think the route cause is the rubber weather seal, its got metal clips on it which i suspect damag the paint work when fitted.....water gets in and rust starts.....worth squirting some waxoyl under them if you can get the tube under it (which should also help stop the rust spreading....)

[nixoro]

Another one I found was today under the doorstrip on the diver side passenger door.

Cleaned this up today, still needs spraying but looks alot better than it was.

Filler still needs to set.

Need to get my hands on some cutting compound.

Worth checking, pain to get to.

[markrl]

Many thanks for the replies. Took the rubber window seal off, there are no metal clips on mine just a very tight fit with a large lip on the inside. I suspect the rubber seal may have a metal rod inside for rigidity. It looks like the corrosion starts on the inside of the door, very small area not more then 1/4 inch in length and under the seal. I would be interested to know if the later models were galvanised on the doors at this location given that it appears such a vulnerable area. The Senator for all its other corrosion frailties had a much better setup then these horrible rubber window strips which seem so crudely designed. I will see what the body shop says, then maybe its time for the big trade in, pity because otherwise it’s pristine.

[Markie]

got exactly the same problem in exactly the same areas, and i think  the facelift were about 75% galvanised, not sure where though...