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How Do I Repair an Entry Door That Is Rusting & Corroding on the Bottom?

Tzvi Raphael

A metal entry door is a strong, durable option for securing your home against break-ins and the outdoors. The only problem is that it's susceptible to rust and corrosion, especially the bottom part, as it is easily reached by water or snow. Metal doors often have a protective metal kickplate along the bottom to protect them from moisture damage, but occasionally the damage is done despite this protective measure. You can, however, repair a metal door and restore it to its original state.

  1. Place the point of a nail against the tail end of the hinge pin. Bang on the head of the nail with a hammer to force out the hinge pin. You only need to move the pin out of the hinge by 2 or 3 inches.

  2. Set the tip of a screwdriver under the hinge pin head and tap the handle of the screwdriver with the hammer until the pin comes out. Remove the other hinge pins in the same way.

  3. Pull the door from the doorframe. Lay the door across a pair of sawhorses, corroded side up.

  4. Remove the metal plate with a power drill to expose the door underneath.

  5. Clean the rust off the exposed part of the door with an orbital sander, using fine sandpaper. Run the sander along the edges of the door if there is any rust there.

  6. Paint the clean, sanded part of the door with whatever paint or other finish you have on the rest of the door and let it dry for 3 to 4 hours. Drying and/or curing time varies from product to product. Consult and follow the instructions for the specific product you are using.

  7. Run a bead of silicone all around the edges of the back of the new kickplate. You only need enough silicone to seal the plate against letting in rain or snow.

  8. Turn the kickplate over and set it on the door in the same position the old one was in. Gently press the plate down so that the silicone can bond.

  9. Insert a screw into each of the holes on the kickplate and screw it onto the door with the drill.

  10. Reinstall the door on the hinges and drive the hinge pins in to hold the door in place.