I did a search, but couldn't find any info, what is the best way of dealing with rust in the channel of this door?
Cut it all out at each end? It'd be difficult with the way the frame is shaped, or is there a trick?

If no good options, what's the best way to find some more doors? It was hard enough to get these, this rust wasn't visible with the trim fitted, they both have similar rust there

It's just been sandblasted, and there are small holes all along

Doesn't look too bad.
I would braze it up with nickel bronze wherever there are holes. Then POR15 it.

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DrMini- 1970 wasaMatic 1360, Mk1S crank, 86.6HP (ATW) =~125 @ crank, 45 Dellorto (38 chokes), RE282 sprint cam, 1.5 rockers, 11.0:1 C/R.

I would be concerned that its starting to bulge with the rust I would cut out the panel and clean it properly and put it back in

I chopped it out! I don't know how I'd get it back in, and still water tight, but I figured it was basically a scrap door anyway.

The channel seems to be spot welded in, and looks like it would be many hours to separate, repair, and then reassemble

Minispares have Doors for 483 pounds, which after buying these seems not that crazy, maybe, still a hell of a lot of money

The bottom of this door needs a large patch under the bin also, but the skin is sound, just a few isolated pin pricks that I already repaired. Still too far gone I think

What solution can Minisport there in Adelaide offer you?

So, I made up a new rain channel from some stainless square tube, which I then tacked a stip on to slip under the doorskin edge.
The new folded panel for the interior of the door is flat, where the original had a bead along the top edge. I welded the door latch section onto the new panel.
The last photo was from after test fit, the doors were only roughly skimmed with filler, they will need rubbing back and more work before paint.

I also welded in some new sections in the bottom of the doors and plugged some pinholes. I hope with a good coat of paint they will last a few years, but I see a new pair of doors in Susanna's future.

that'll do the job nicely I reckon, great work

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did I tell you that I won a trophy?

Great work will copy that on my doors

Great sheet metal work again Andrew ! Good to see Suzanna getting some more attention.

When you say you welded the bottom of the door, was that a patch mig welded onto the pocket ?

When you say you plugged some pin holes, did you braze them or do you mean plug welded ?

I've got no welding experience so sorry to ask silly questions.

Any photos of these other repairs ?

What are the specs on your welder and what is the thickness of metal you can weld ?

cheers

The Patching was on the bottom of the door frame, the pocket didn't have any rust, probably because it's higher up, and would drain any water away.
I think I MIG welded most of the patches, there were actually a few of them, I used a MIG because the remaining rust means that it wouldn't have been clean enough to TIG
I MIG welded the pinholes, it's kinda dodgy, really should have put more patches in, but I had to draw the line somewhere, that's why I don't think these doors won't last forever, the amount of rust in these doors means I've just bought some time.
No photos, sorry, already skimmed filler over the outside, and the inside wouldn't photograph well

I have a Jasic 140 amp TIG, and a WIA 180 amp mig.
These machines are probably starting to run out of power when welding 8mm steel, 6mm is about max really, they're both small single phase welders.