Replacing Door Pilars

[kjmssd]

Does anyone have any great ideas on how to replace my door pilars? I have taken measurements, marked the location and measured all of the angles that I can think of. This is a frame off project. There is just too much rust under the pilars to ignore the problem. Luckily the hinge mounting plates inside the new pilars allow some adjustment because they move around. Even still, I want to be as precise as possible and I want my doors to close properly.

One of my biggest questions is how to align and attach the new pilar to the dash and the window frame. I am also replacing the inner and outer rocker panels which attach to the door pilar.

 

[jon-r227]

I am just working on this same operation. Two tips that others have shared: make sure you are braced up well and cut out the old metal carefully (I went a bit gung-ho on mine, but there was so much rust some parts were fused together). There are a few posts on it, this one has some good info. http://classicbroncos.com/forums/showthread.php?t=158948&highlight=door+post

The passenger side went back together fairly easily but I've been struggling with the drivers side. Mainly because the kick panel will not line up with the inner fender. Its going to require trimming, which others have said is necessary, but I don't understand why. Now I've got to figure out which part of it I want to trim.

The way its all put together is the inner rocker (basically a flat piece of metal that is a little wider than the doors and extends below the floor 5-6") has 90 degree angle on it that fits over the edge of the floor pans and seat platform. It provides a flat area for the kick panel and door post to weld to. Finally the outer rocker welds between the door posts and to the inner rocker. You basically have to find the spot welds and remove each piece, assuming you're going to replace them all. If not its just a matter of carefully cutting the outer rocker where it comes up to meet the door posts and then drilling the spot welds that hold the door post to the inner rocker. At the dash/windshield bracket it's a little tougher to figure out how it all fits but if you cut/grind it out slow with the new post in hand it isn't too tough.

I've got to do the rears as well. I want to get the front posts set first though so I don't have too many variables.

 

[fordguy]

i was able to cut out the lower parts of the front door post and patch, see my build thread http://classicbroncos.com/forums/showthread.php?t=188757&page=5&highlight=it's+official+build+thread
its probably not going to look like factory going back together and you will have to trim fit, beat, bang, massage. if you have access to a plotter you can get some wall pics of the dimensions (there is someone on here with diagrams) and put those up to reference. measure twice cut once %) ask me how i know