I've just discovered a huge rust pocket on the drivers door frame under the rubber gaskets near the mirror, before starting to do anything and taking the door apart I'm looking for the advise what is the best way to fix it. Obviously I don't want to buy a new door - do you guys think it is fixable?

Thanks

 

we have tried to fix these at my work once you notice the bulge in the rubber it is too far gone you can pull the door apart and sandblast but it will come back. we have replaced a few under the 5 year rust warrenty but i am sure yours is up unless you purchased extra rust protection,you may have to buy a new door sorry honda had the same problem on the 99-04 ody too

 

The year, model, etc would be helpful.

I think that once rust starts like that, it will be tough to stop. You aren't even sure how much rust is in there.

I would go to a site like car-part.com and check for junkyard prices. You can sort by price or distance. It may be much cheaper than you think to replace a door with the same color. It helps that there are a lot of accords out there for salvage.

 

Thanks for suggestions, I've found a door from the local scrap place really very inexpensive 120$, then guess what - it had a rust pocket at exactly same spot!
I will keep looking, in the meantime considering other repair options like welding or epoxy? Is that upper frame around the glass welded solid to the door panel or are some removable components there? I hate to take things apart without knowing how are constructed.