Flyscreen restoration

a586

Hi guys! Would love some tips on my plan to restore our entire flyscreen. It has been on our door for 30+ years, is slightly decorative and has three dead-bolts, so we'd like to keep it. I've attached some pictures to this post for you to see what I'm talking about.

The flyscreen mesh has completely come away, and some areas of the door are rusty. We live near the beach, so salt spray and rust is an issue we experience.

I've done some research on how to restore it, and this is what I'm thinking of doing. Please let me know if you recommend I do anything differently/have any advice for me. I'd really appreciate it as I've never done anything like this before.

The plan is to:

1. Take the flyscreen off the hinges, take the remaining screen off, give it a rinse with some soap and water and let it dry.
2. Using a "Scotch-Brite Clean & Strip disc" (or something similar) on the angle grinder, I'd take away the old paint and rust. For the parts I can't get to using that, I'll just use a hand file.
3. To fill-in the rusted parts, I'm assuming I need some metal filler that could help with the holes. I need advice on what would be best to use here. I don't have a welder so patching it I think is my best bet.
4. Once the holes have been patched and everything is looking good, I'd like to use a rust-protectant on the metal to help protect it from future rust. Would need advice here on the best one to use.
5. Will then be using some kind of black spray paint to finish it off. I need advice on the best one to use here as well.
6. Finally, I'll be attaching some "pet mesh" as the screen, as we have a dog who loves to scratch at the screen and this is apparently good stuff to use for that.

Notes: would love to change the handle, but don't know if that's possible. Worst case scenario if that's not possible, I'd like to paint it black. Any advice here would be appreciated too.

Images are below:

JacobZ

Hi @a586,

Your process is pretty much spot on.

Start by removing the door and the existing flyscreen and giving the frame a good clean. Just make sure the door is completely dry before moving on, as any leftover moisture or salt residue can contribute to future rust, especially being near the coast.

Using a stripping disc such as this https://www.bunnings.com.au/josco-125mm-purple-multi-strip-disc_p0413235 is a good choice for removing old paint and rust. Just be mindful not to be too aggressive on thinner sections of the frame. For tighter or more detailed areas, a wire brush or sandpaper can give you better control.

For any filling that is required, https://www.bunnings.com.au/turbo-500ml-metal-builders-bog_p1210384 is what I'd recommend. It is sandable and suitable for exterior use once painted.

After prep, applying a rust converter such as https://www.bunnings.com.au/white-knight-rust-guard-125ml-rust-converter_p0163911 in any areas where rust staining remains is a great idea. Following that with a quality exterior metal primer such as https://www.bunnings.com.au/white-knight-medium-grey-500ml-rust-guard-metal-primer-paint_p1564207 will help protect the surface and help your topcoat adhere well.

For the topcoat, I'd suggest using https://www.bunnings.com.au/white-knight-rust-guard-310g-black-gloss-epoxy-enamel-spray-paint_p1561869 to finish off. It is a quality epoxy enamel paint that will offer some solid protection to your door.

Pet mesh is a great choice for durability, especially with a dog. It’s much stronger than standard mesh. It’s also worth checking the spline that holds the mesh in place and replacing it if it’s worn, so you get a nice tight finish.

With the handle, replacement may be possible, but it can be a bit hit and miss with older doors. If you can’t find a suitable replacement, giving it a light sand, priming it, and painting it is a perfectly good option.

It's a solid plan and I hope this helps to clarify any questions you had. As long as you use the right products, the key to getting a good result, will be thorough prep and using the right primer and protective coatings.

Let me know what you think and if you have further questions, please don't hesitate to ask.

Jacob