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Old 10-22-2008, 01:29 PM
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Default Stopping rust on a wood core steel door.

In the last 1.5 years I have spot treated my rear entry door. three times. First two times I did while it was on the hinges. The last time I took it off completely, on saw horses, removed the rubber threshold sweep, even cauled the metal/wood seams underneath. All three times I sanded to bare metal, and applied, Kilz, Zinsser, and Rustoleum repspectively. The spot is coming back, never larger than a dime but it's only a matter of time... What gives?!?!
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Old 10-22-2008, 01:52 PM
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Default RE: Stopping rust on a wood core steel door.

Treat the bare metal w/ Duro Extend(not the other stuff) rust inhibitor before painting.
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Old 10-23-2008, 01:38 PM
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Default Re: Stopping rust on a wood core steel door.

Good luck Birdy, my solution is to replace the slab with a fiberglass one. If you're anywhere near salt, they don't last long.
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Old 10-24-2008, 11:48 AM
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Default Re: Stopping rust on a wood core steel door.

I have been selling this type of door for many years. If it is a normal residential steel unit; not a high end clad wood; it will be foam filled inside a wood perimiter frame. If you have a glass insert of any kind in the door, chances are it is leaking, allowing water to penitrate to the core and rusting from the inside out. Also condensation could be occuring on the inside of the steel door skin. BIGnUGLY was right, your best bet is to live with it as long as you can, then replace. If the door jamb is not rotten; check the bottom 6 inches; the door can be replaced relitively cheaply. In this area a 6 panel replacement slab runs about $70.00. A fiberglas replacement starts at about $150.00, differant glass options can add up to $100.00 for an insert. In my experiance by the time the door needs replacement usually the jamb does to, add $60-$100 depending on the jamb specs. 1 hour job for a carpenter for slab replacement, 3 hour for whole door unit.
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Old 10-24-2008, 02:45 PM
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Default Re: Stopping rust on a wood core steel door.

Had the same thing. Never did get a total control on the rust. Sanded down bare metal, rust converter, primer, rutoleum.
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Old 10-24-2008, 07:44 PM
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Default Re: Stopping rust on a wood core steel door.

Thanks all. Blackswamp you're right it has a 15 panel glass insert, bottom seal outside has pulled away from the door, probably allowing water intrusion. You have a PM.
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Old 10-25-2008, 06:44 AM
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Default Re: Stopping rust on a wood core steel door.

If the sash is leaking, allowing water to run down the inside of the door, the outer skin of the door will have separated from the foam core (inside the door). Tapping on the skin of the door with your finger will allow you to identify the bond between the metal skin and the foam core......you will hear the difference without doubt if there is a separation. If there is any separation replace the door panel. Another way to easily tell if a sash is leaking is to pop the hinge pins and lift up the door. If the door weighs a bloody ton then you know the sash is leaking and the door is full of water. If the door weighs a ton then replace it because the core will be offering you zero insulation value.

As far as the reoccurring rust problem goes, do the repair work as you have in the past, but before you reinstall your sweep lay down a bead of silicone caulk on the newly repaired area and spread it out to the width of the sweep and then slide on your sweep....clean excessive caulking. The caulking will do two things. One stop water from entering between the sweep and the skin and secondly stop air from activating rush if moisture were to find it's way to the repaired area.
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Old 10-25-2008, 10:01 AM
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Default Re: Stopping rust on a wood core steel door.

Garett good points. No detectable separation as of yet. The rust spot is in the very lowest right hand corner and at it's worst was no bigger than a dime in diameter. 6-8 swipes of sandpaper got it to bare metal everytime. The caulk idea is good. I just caulked the one edge instead of all the way down. Depending on costs I may just replace the whole freaking thing. Fiberglass rules!


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Old 10-26-2008, 02:29 AM
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Default Re: Stopping rust on a wood core steel door.

I have to say, there is some pretty damn good looking fiberglass doors on the market today.....we've been shopping around for a new front entrance way.

Scotland......in a nut shell......should have made the move years ago, we just love it.
In a few weeks when I have a little breathing space Iíll post up some pics of my recent property improvements.
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