<VV> Rust Devils

[Arjay Morgan]

I seek the group's knowlege in a vexing rust problem.
   
  A year and a half ago I took the 64 Monza down to bare metal via media blasting and Vaun Hamlin and I repaired every dent, ding and rust spot before repainting the car.
   
  Yesterday I discovered rust pustules pushing out the paint in two small spots on the bottom, front corners of both doors. As I recall, this is an area where the door skin metal folds around the door's subframe. It's right IN the corner, not an inch or two away, so there's no practical way to get behind the rust. I suspect that the rust is originating between the subframe and the skin where everything is welded shut.
   
  One Corvair friend opined the only solution is to get two new doors or re-skin the old ones or get replacement patch panels. That seemed a bit extreme since the spots are less than 1/2" in diameter.
   
  Does it seem reasonable to grind into the affected area until I hit good metal and then use the POR-15 system to stabilize the area that's rusting behind the doorskin, then use the new epoxy-based body filler to bring the surface back up ?  My preference would be to use body metal and epoxy or weld on the backside of the panel, but I don't think that's possible because of the extreme corner location.
   
  Has anyone dealt with this problem before? And what is the solution?
   
  Thanks in advance,
  Arjay Morgan
  64 Monza Convert.

		
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