Rust repair

[Pin_Head]

I threw in the towel on finding good used doors locally and bit the bullet by cutting out the rust and welding in new sheet.

Cut a piece of 16 ga sheet and bend and pound it into shape.

Check the fit often

Out with the rust, in with the new

Tack weld and then fill in the gaps. If the metal warps, peen the weld bead with a chisel point hammer across the bead to expand the metal.

Grind, fill, sand

Paint

Done. It needs some finish filling and sanding before the top coat is applied. About 4 hours, total, not including the time for the filler and paint to dry.

 

[Texx]

Been there, done that, x1000. Your finished patch panel looks pretty much identical to the free ccot ones I got with the last 40 I bought. I only used a small piece of each one, so I could fix more doors as they come along. Nice work!

 

[osagecruiser]

nice work pinhead...also been there only the repair was the result of a neighbor backing into jake.

osagecruiser

 

[Wile E Coyote]

Looks good, BTDT too, and used my vice, as well. Mine was on the rear lift gate on my 62. I used a couple homebrew forming dies and a hammer.