Back at the doors. I never thought I would ever get this backwards in an FJ40, but here we are. I purchased these doors from a mud member, as mentioned that were supposed to be clean and near perfect. Come to find out they are hiding more than the current administration under the paint.
It is also frustrating that there are more options on the market to day for a set of doors, but digging into that doesn't do much for my current situation.
The other problem with these doors is they were re-painted and worked on in an apparently humid area and not prepped, so there is surface rust all over the steel. Thus, the doors need to be completely stripped. Another annoyingly difficult job.
However, to seal up the bottom of the driver door - the outside was spottable and given the heat/warping difficulties decided to leave it alone. The inside needed to be patched however.
I poked all around with a screwdriver to find any weak areas and filled it in with the welder:
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Once that was done it was fairly easy to grind smooth to a point where the exterior of the door will turn out really nice.
On the other side of the firewall, Olive, our new Golden stood watch. At many other various points in this thread, you can see Lola, who we lost last year. I never was a "dog lover", but Lola broke me and when we lost her and I had to carry her away - I knew Olive would be inevitable. So, here she is.
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Tacking in the new bottom area. The "ridge" of the Real Steel door bottom is more aggressive than the original door, so as I am spotting those areas in, I used a body hammer to tap/blend that ridge down. I guess the only real good news here, is that these are original Toyota doors.....and will have good steel in them.
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While doing some yard work, I'd let it cool...go rake...come back, tack a few more....lather rinse repeat until it was all filled in. (I used weld through primer generously on the inside of the mating areas and will also fluid film the inside when all done.
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Ground smooth, ready for additional paint removal/stripping and then epoxy primer, filler, and more fun.
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Also, I am planning on removing the air injection rail, engine hooks to have them properly zinc coated. The gold rattle can is unbecoming of the level of detail I wanted here, and stick out in all of the wrong ways. I plan on properly addressing this in the weeks to come, when I get a small stack of things to drop off at the shop.
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all the work you have to go through, but I 
