How to splice repair corroded bottom 100mm of my external shed steel door frame?

[rossvm]

[Dave-1]

Afternoon @rossvm 

Welcome to the Bunnings community and that is an interesting question.

Is it just the outside of the shed door? As in there is no structual part on the inside that has rusted through?

If its just the outside covering then I would cut it square maybe half way from the second left rib across so all teh rust is gone. Then I would source some same profile sheeting and cut a section a little taller and wider and slip it under the cut line, then pop rivit the two together like stitching. That way the water will run down and not inside and will be secure.

If the rust extends to a support post then we will come up with another idea.

Dave

[rossvm]

Thanks for your quick reply Dave.

The door frame is to the outside and supports a few courses of bricks above but it isn't really structural as the roof rafters are supported by the brick shed walls.

Sourcing a section of the same profile metal is where I'm having a problem. Bunnings don't seem to carry steel door frames or lengths of steel door frame material to make make a frame or do a repair. Any suggestions on where I can get this in Mandurah WA?  While it wouldn't be as good I could do the replacement section in timber. Or even cut out the rusted part and fill with an epoxy product. Any thoughts on these ideas?

Thank you.

[EricL]

Hello @rossvm 

Welcome to the Bunnings Workshop community. It's sensational to have you join us and thanks for sharing your question about your steel door frame.

It's great that you've received excellent advice from @Dave-1. The metal door frames available at the store have a totally different profile from what you have. However, your suggestion of using timber and using Builder's Bog is a good alternative especially if you can't source a replacement piece. If you are using timber, I would suggest fixing the steel skin to the timber patch with screws and using a waterproof primer to give the timber an extra layer of defence when it gets wet.

If you go for the Builder's Bog, just make sure not add too much activator so that you have a lot time to sculpt the bog into the proper shape. Make sure to overlap the steel so that they blend together.

If you need further assistance, please let us know.

Eric