Fixing rust spots on body? -
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post #1 of 4 Old 09-12-2013, 01:19 PM Thread Starter
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2004 TJ Wrangler 
Join Date: Dec 2009
Location: Central Florida
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Fixing rust spots on body?

I have some rust spots developing on my door handles and doors. Im not too worried about the door handles since those can be easily painted/replaced but i just noticed a rust spot by my window, how can i fix this so it doesnt spread and get worse? Thanks.

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04 TJ Sport- Kicker System, Smittybilt XRC-8 Winch, Cherry Bomb 18" Glasspack, 3" Zone Hydro Suspension Lift, 33x12.50 BFG KM2, 15x8 Procomp 7069, Aussie Locker front Dana 30, JKS 1.25" Body Lift, 4 100w Hella 500s
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post #2 of 4 Old 09-13-2013, 02:05 PM
2004 TJ Wrangler 
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Not good news as that is a small crack that will continue to grow. Welding it and repaint is the permanant repair. That happened to many YJ doors and now seems to plague TJs.
Sorry to be the bearer of bad news.


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post #3 of 4 Old 09-14-2013, 06:05 AM
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Beware..thats not a weld. Its applyed like a weld though. It is in fact Silicon Bronze. Its normally not a crack. Its the inside edge of the door skin rusting and bleeding through under the bronze apearing to look like a crack. Unless ofcourse theres clear evidence of damage and a crack. But typicaly its the edge I mentioned above. To fix it would be to clean the area best you can and prime and paint or at least seal it with some touchup. The bronze was dressed with 3" soft pad grinders. It tough to get into that inside edge to smooth without maring the door frame or skin. Therefore the result is the appearance of a crack sometimes. But its not. Hope that helps.
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post #4 of 4 Old 09-14-2013, 06:20 AM
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Looking at your pic more it does look like it might be cracking by the looks of the rust going over the edge of the panel. The spot at the bronze is typical and a flex point when door shuts. Maybe check your seals and make sure their not getting hard and cause harder door efforts when shutting putting unnessasary pressure against your door and door frame to relieve some of that stresss. Unfortunately if it were mine I would look to sand blasting that area best you can and rebraize and prime and paint. Its location is going to be tough to stop the rust unless blasted or dipped. You can make it bettter but not correcting the problem unless you can clean inside and out of rust.
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