Rust on metal door

[Mark Katz]

About 15 years ago I had this metal door installed as the the "man door" to my garage/workshop. I think the door was primed, but not otherwise painted, but not sure. In any event, in my hurry to get back to woodworking, I just left the door as is. As you can see, it's developed quite a patina.

Looking for advice on how to most easily remove the rust and paint the door. I'd rather do this without taking down the door but I can if necessary. If I do need to take it down, it needs to be rehung within a few hours.

i do have an ROS and an RTS400 if sanding is needed.

Thanks, Mark
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[Vtshopdog]

I refinished a similar metal door a few years ago but my rust area was much smaller than yours.

I would sand it, maybe apply an acid etch (available at auto paint suppliers) to kill any remaining rust, prime and paint with your preferred top coat.  Auto refinishing supplies are your friend for outdoor metal painting.  Sand-able primer available if you care about final finish and surface imperfections.

Needing to use door in a few hours might complicate your choices of top finish.