Never ending door repair
Hand formed patch for the door skin
Tacked In
Welded In
Weld ground with cut-off wheel
Angle grinder with 24 grit wheel followed with 80 grit DA. With a little more work this weld would not be visible at all. I am going to stop here because I will skim the whole door with Rage to get rid of all the minor surface flaws so its not worth the effort to make the weld disappear.
Now to correct the factory build flaw. Spot weld drilled out. It took quite a bit of effort to bend/beat this flap back under the door fold where it belongs.
I spot welded the door skin and inner door structure as the factory attempted to do. I put a weld bead down the fold of the door skin to rejoin the lip where it was folded over and broke. This part of the repair would had worked better by TIG welding, but came good anyway. I have a TIG but it was buried under in a stack of body parts. And then TIG welding is very slow.
Next the last part of the rust repair.
This is what is looked like on the surface
This is how much I ending up cutting out.
And then the corner of the door skin because it had almost rusted through from the back side.
The patch is almost ready. It's getting late so I calling it a night. A few more minute of bending and it will be ready to install.
In between door repair I mounted the driver side seat. I will show pictures of how the seat frame was modified later. For those of you who thought I had black seats, I did, but I used them in a company van and then replaced them with blue seats. Unfortunately I have to modify seat frames again.
And UPS brought more necessary parts today. I decided that the wiring in the original dash harness was too brittle and bought a new harness. It's better to put the dash harness in now rather than redoing it later.
