Sadly last night was the last night of my tafe class for this semester, my goal was to get the door skin on before the end, but alas as you can see below I didn't quite get there. That's ok though as I didn't want to rush the job to completion and I am almost ready to put the door skin on.
So after sandblasting the door again (to get rid of built up surface rust) I actually managed to put another rust pin hole at the bottom of the door due to the pitted metal in the bottom corner of the door.
To repair it I attempted to use a mig-welder to patch it up, but because the metal is so thin in this area already due to pitting etc.. I actually blew holes through it and it took a bit of persistence to try and patch it up again. In many ways doing this is like chasing your tail and I very nearly decided to just lob off this section and fabricate a new lower piece of the door frame.
As you can see it's a bit messy looking, and whilst it won't be an area that's highly visible I'm still on the fence as to weather or not I'll use a bit of filler to smooth it out, or weld on a new section here.
You'll also notice that it's now in epoxy primer - this was done in the paint booth at Tafe.
There is still some surface areas with imperfections that will need a bit of filler to smooth out, but I decided to put it in epoxy first to prevent having to blast surface rust off each time.
As you can see the door shell turned out quite good. Considering how it started earlier in this thread .
The next step is to apply some seam sealer around the door hinge area (where that extra bit of metal is that the captive nuts sit on) and then use some Anti Flutter Foam on the side intrusion bar. Both of which were removed during media blasting.
I may also use some KBS rust proofing paints (rust seal) on the inside of the door to help seal her up for good and prevent the rust bug from returning - that bastard!.
http://www.kbs-coatings.com.au/product/rust-seal/
Will keep you updated when time comes to put the door skin on. But I feel like the majority of the work here is behind me now. Thankfully! Hopefully you're also getting an appreciation of how much work is involved in fixing these areas also.