upper door panel repair vs replace (pics)

[backpain]

Alright, if you're gonna have to pay $50/hr to fix this door, do you patch and refinish or pay $450 for a new shell w/window frame and then paint the entire door?

Issues:
- upper door panel where it meets the window has approx 3 tears and/or stress cracks; also I want to fill in the stock/PO mirror mount holes
- PO has done some prior work to repair damage or at least move the mirror mounts or refill prior holes
- the metal is too thin to simply weld up the cracks, so at minimum a patch panel will have to be used
- the rest of the door is great shape in and out; windows, latches, etc all work and are installed
- while though it is already painted I will eventually repaint; it's currently in good enough condition other than noted above to sand and repaint without significant repair work
- the door currently lines up well with fender and qtr - it's a toss up whether a new door will require panel fitment

Replacing the entire skin seem harder than it's worth. Buying a new complete door shell will require swapping all the guts and hardware, as well as refinishing inside and out. Additionally, I have no idea what possible unknown fitment issues I will run into with the replacement door.

Opinions?

Here's a few pics of the damage (the brass color in the first picture is just a refection)

 

[Revelation]

First thing I would do is strip the rest of the door, bet you find more filler!

 

[backpain]

First thing I would do is strip the rest of the door, bet you find more filler!

from the inside with the interior panel and the window removed, it actually looks in good shape - no rust, no patches, no holes with filler bleeding through, no apparent dents that have been hammered back out. . . .

part of the window frame was either replaced or repaired at some time, but strength is there

 

[taipeichris]

Hi,
I'd find someone with an old door that is rusted out at the bottom and take a "clip" of the top matching what you need to replace and get someone to weld it in. Even if you do fill the wholes, it might not be as strong. Try posting in the "Parts Wanted" section and see if you can get the sheet metal clip.
Just my 2 cents.
Chris

 

[backpain]

Since I don't have to replace all the way to either leading or trailing edge of the door, the patch can be pretty easily made by rolling some sheet metal to the correct contour - alternatively, I can buy a new door skin for $1xx and have my metal shop create the patch from that.

I just don't know how much work it will be to blend it all in . . . .

 

[fordtrucks4ever]

Just back up the crack(s) with a piece of sheetmetal from behind. That way you can have good penetration, no burn thru, and stiffen the area too. You dont need to cut up a donor to get something that will work. 20ga or even thinner is easy to form and it doesnt have to be perfect, since it wont show. I would even bend the piece with a sharp angle so it reinforces the lip where anti rattle clips in. If the guy doing the work is worth $50 an hour, it wont take 30 minutes for him to fix.

 

[Heus33]

I'd get a quote first - then compare the price of the repair to the price of a new door. Also factor in the offsetting cost of selling that door - its probably worth $100 or more to someone who wants to fix it themselves or use it as a trail door.

 

[Steve83]

My fix would be:
1) panel adhesive (no welding) & patch panel inside; Bondo & paint outside,
OR
2) replacement door (I hate bodywork)

 

[BroncoWanted]

Just back up the crack(s) with a piece of sheetmetal from behind. That way you can have good penetration, no burn thru, and stiffen the area too. You dont need to cut up a donor to get something that will work. 20ga or even thinner is easy to form and it doesnt have to be perfect, since it wont show. I would even bend the piece with a sharp angle so it reinforces the lip where anti rattle clips in. If the guy doing the work is worth $50 an hour, it wont take 30 minutes for him to fix.

I agree. I would use a backing piece and weld the cracks up and then use body filler to smooth everything together. If you plan on re-painting in the future why waste the money now. Wait until you re-paint and then reevaluate the cracks and whether or not to replace the door. just my .2