Door Rust Repair Questions from a Newbie

Gweiner · Mar 2, 2013

Hey guys - want to tackle the biggest problems first. Fortunately, there is minimal rust on my 74. The doors are the worst of it. Please see attached photo. Rust holes through the bottom of the doors only. My questions are as follows:

(1) Repairable or look for some other doors?

(2) Do door skins cover the bottom of the door or just the outside? Stupid question I know.

(3) DO they make/sell sheet metal patches or is this something that needs to be custom fabricated?

Other than the rust on the bottom of both doors, they are in reasonably good shape, with no other issues, maybe 1 dent.

Appreciate any and all advice here.

bronconut73 · Mar 2, 2013

One of the vendors sells the bottom of the door body. Skins are just the outer skins. Save the door or not? Well only you can decide but look around for some used doors. Maybe their price will be the deciding factor.

Gweiner · Mar 2, 2013

Searched hij and low on every vendor's site for lower (underside) patch panels. Nothing. Only thing I see ate complete door shells for $500 each...

AZ73 · Mar 2, 2013

Get a used door. To repair that is a nightmare. Do a search on skinning a door and you'll see what a pain it is for a novice and you'll have to do that to repair your door.

Gweiner · Mar 2, 2013

Thanks. Starting to that myself. Was thinking of cutting out all the rust and trying to bend some sheet metal and tac into place to minimize bondo but not sure it will work or I can make it look halfway decent...

Desert Dweller · Mar 2, 2013

Here's what I did when faced with that on a pair of doors we were makinto trail doors... No, I didn't mud over the cardboard. Used that for a pattern, then cut a piece of sheet metal from the pattern. Tacked it on, then hammered the corner around and booger welded it in. After all the repairs were done, shot the inside of the door with POR15... Should last a few years at least. And on trail doors will get completely destryed anyway. For you, this would be a way to fix it for now so you can find nicer doors and not have to make a desperation purchase.

(also a quick video after welding-- camera man pushed the wrong button %))

Gweiner · Mar 2, 2013

Great idea! Thanks! I may try the template. I have some por 15 left too.

Thanks gain!

sp71eb · Mar 2, 2013

Lmc truck has the door shell lower portion. 49-7792 I would say if you use it your going to have to skin the door. Welding in the entire lower section of the door will take a decent amount of skill and hopefully the replacement part is decently stamped and formed to begin with. Not sure if you have any body work experience but I would say sectioning a door isn't a great place to start.

1971Bronco1971 · Mar 2, 2013

I was in a similar position as you and I was going to reskin them, and I was much better going with new doors, and mine actually looked a little better than yours. Just my 2 cents

wheelsblank27 · Mar 2, 2013

Get some used, prolly cost 500$ for both 100 +-, if yu haven't done a few patches on flat sheetmetal, don't go skinning that cat yet.

u10072 · Mar 3, 2013

Remember the door skins are not flat they have a curve. Not much but it's there. Weld flat to curved and you now are going to ruin the door. Get new doors and sell yours to the door.

Door Rust Repair Questions from a Newbie

Gweiner

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bronconut73

Bronco Guru

Gweiner

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AZ73

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Gweiner

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Desert Dweller

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Gweiner

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sp71eb

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1971Bronco1971

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wheelsblank27

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u10072

Bronco Guru

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