bottom door inner rust

[brad smith]

about to tackle a job. the bottom inner of my 74 bronco door is rusted. how would i start and with what tools can i use to seperate the outer skin from the inner skin with out damaging the outer skin thanks in advance brad

 

[pcf_mark]

Does the rust reach to the outer skin? I have "rare" 66-68 doors and I wanted to save them. The driver side was rusty in the inner door but the skin was good. I cut away a 3" wide by about 16" long section of the bottom of the door (back half) and formed a new section with basic tools (hammer, dolly, vice, stretcher, patients) and welded it into place. Once I cleaned up the welds it was pretty solid.

The real trick was to use an Eastwood stretcher

https://pitstopusa.com/i-14357916-e...MIh4Xk37KN2AIVRksNCh1P-Q6JEAQYAyABEgKdpfD_BwE

I bent the section 90 degrees first then ran it through the stretcher a million times and it curved (my section included the curve at the back of the door to get a solid repair)

https://garage.eastwood.com/eastwood-chatter/channeled-bench-seat/

 

[Pa PITT]

Sorry but I'd say just buy some different doors.. About 8 hours of time & you ain't done. So get a set of doors that you can control in about 4 or 5 hours. No need putting 40 hours into a door.

 

[STalon89]

It depends on how far gone it is. You can find a factory door for a few hundred bucks that you can sand and do minimal body work to. Aftermarket never fit right, but doable. Just depends how you much your free time is worth.

 

[brad smith]

i started this project last night. the door is in great shape except for the corner on the hinge end. gonna tackle it. i dont have nothing but time. gonna post pics later

 

[brad smith]

Sorry but I'd say just buy some different doors.. About 8 hours of time & you ain't done. So get a set of doors that you can control in about 4 or 5 hours. No need putting 40 hours into a door.

but doesnt that take the fun out of it. lol

 

[pcf_mark]

Reminder to use weld through primer on your seems / joints and a high quality two part primer on the inside when done. This way the door will not rust out once you are all done fixing it.