I have a badly damaged passenger door that has rust as well. The cheapest route for me seems to be finding a replacement door assembly from a junk yard which I actually have done. My question is how straight forward is removing the door? Is it simply removing the bolts connecting the door to the hinges after removing the interior trim panel? Any help would be greatly appreciated.

 

Yep I would gut the door first. Remove int panel and unplug all ele connections. Pull the wire harness out of the front of the door. Support the door with 2x4's or a floor jack and remove the mounting bolts. Its much easier if you have a friend helping you hold the door when you get to removing the bolts

 

Thanks! Now I just need to figure out how to disconnect the wire harness. Shouldn't be too big of a deal.

 

roll a couple layers of ductape around the fender edge/rocker and the edges of your replacement door to minimize risk of chipping the paint. wax it first so the tape peels off easy. if you take the window 'scissor' out, BE CAREFUL. the first one I ever did years ago surprised me- they are spring loaded, lucky I didnt lose a few fingers...make sure its not loaded, wear gloves, etc...