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Door repair

Bdhand

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Aug 15, 2015
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Anybody got any pics or advice on how to repair the bottom of a door. My drivers side has the usual holes along the bottom of the door. Any suggestions or help would be appreciated. Luckily my passenger door is in great shape. Thanks in advance.
 
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Bdhand

Bdhand

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Thanks for but that is for the skin. I am talking about the bottom of the door. The skin of my door is fine just the bottom has rust.
 

markw

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Sep 10, 2009
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I'd cut it out and weld in a patch panel. I don't think anyone makes a repair panel for that.
 
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Bdhand

Bdhand

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What size metal do you think that is at the bottom of the door?
 

Attac

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Jun 29, 2015
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Most sheet metal on these are approx 18 ga
 

markw

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Good call Rusty, I didn't know about those. Might be the ticket if the whole bottom is gone. If it can be patched without taking the door skin off it would be much easier. BD, do you have a pic of the rust area?
 
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Bdhand

Bdhand

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I will get one this evening and post it here.
 
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Bdhand

Bdhand

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Here are some shots of the rusted spots. I am thinking about ordering the patch panel from Dennis Carpenter that is mentioned above and just cutting out what I need and welding it in. What do you guys think. I wouldn’t have to use the whole patch panel just use what I need.
 

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Rustytruck

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Feb 24, 2002
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10,875
Before buying the expensive lower patch panel I would cut a strip about 1-1/2 to 2 inch wide across the bottom and keep it about 1/8 below the inside corner edge. That should cut most of the rust holes out. Home depot may have some sheet strip pretty cheep. Take the strip and poprivit it with 3 pop rivets across the botom of the door and rough bend it to the door shape. Then take a scribe or awl and scratch on both sides of the strip. Then drill out the rivets and cut between the scribed lines. Grind the door up to the scribed lines. Then its just tacking it in every 3 inches working and fitting as you go. Little tacks as you go. Then go back and tack next to your first row of tacks. After about what appears to be 10,000 tacks it should be looking pretty good. Just take your time and let it cool as you go. Alternate your tacks on both edges of your repair strip.

Before you start cutting make sure your not cutting through something important inside the door. I cant believe you have rust through like that without any door rot at the door skin seam. Very lucky guy.
 

bronkenn

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I very seldom use the whole patch panel. Just cut out what is needed. That being said, I would repair that one the way Rusty described. Ken
 

markw

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Kind of time vs money here. Nice to get the radius in the patch panel. Now if I had a fine brake and bead roller or an English wheel it would be run to make a beautiful patch. My hammer on edge of table work leave much to be desired! But that's just me....:)
 

Rustytruck

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I do allot of hammer on the edge of the table work, but after a couple of times of doing that I get splinter when I am eating dinner. At least all this work is under the door so if it isnt perfect who is going to know. Much better than welding on the inside face of the door. Leaving the existing corner edge will make it much easier to get a clean patch. Time over money loos the time and save the money to buy parts that are really needed. weld inches are the same either way unless your re-skinning the door.
 

markw

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Yep! It takes a lot of work to look under the bottom of someone's door to check out the welds! No one is going to see it. Keep it simple.
 
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Bdhand

Bdhand

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Well I just ordered the patch from DC! I just don’t think i am good enough to make the patch! To me it’s going to be easier to cut out the bad part and use what i need of the patch! It’s only 100 bucks so to me the ease of the patch panel outweighs the money at this point! I will post an update when i get it in!
 

markw

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Good deal. Have fun and weld like Rusty says. I like to use a hard grinding disc on edge to take down the welds then finish with a flap disc, coarse, like 36 grit. Light pressure so you don't thin the metal round the welds or go through the edges.
 

Rustytruck

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Feb 24, 2002
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10,875
I like to trim down the weld with a cutting disc cuts down quick. its like surgery then go over it with 180 grit wheel then off to the Bondo phase. Its all about taking your time and not making more work for your self.
 

englewoodcowboy

Lick Creek Restorations
Joined
Jul 25, 2010
Messages
4,200
Check out my build of The Duck in the link in my sig. I go over the door repair in pretty good detail and I used new skins and Carpenters door bottoms. They repair panels are not pretty on the edges but they are repair panels so you cut out only what you need etc. I still prefer to repair an original door vs using a new aftermarket shell. The new shells are twisted and you have to do some work to straighten them so they line up right.
 
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