Today I worked on the Cruiser driver door a bit. I've got several issues to deal with:
- Sticky/hard-to-crank side window
- Crack in the paint/metal?
- Wobbly beltline moldings
- Missing vapor barrier
- Dubious door card
- Completely worn-out old door card trim fasteners that have been reused way too many times
- It would be nice to add sound deadening
I hope to address all of these issues in one go while I have things torn apart.
I started by pulling the side window glass, followed by the beltline moldings. I have new plastic clips, so I wasn't handling stuff like a gorilla, but also figured I didn't need total kid gloves because if the clips break with standard removal, they are probably old/brittle and should be replaced anyway.
You may have noticed the yellow strip; I started sanding where the crack is to see what is going on below the paint/filler.
Yup, the crack looks to be down to the metal.
Going deeper; quite a bit of filler feathered really far out to blend this in.
Hard to tell what is going on in the back side of the crack inside the door, but there is some sort of build up on the back, but not something that bridges/bonds both sides of the crack as I'm able to flex each side of the crack independently of each other.
I think the root of the problem is damage that was never repaired to the sheet metal on the smaller side of the hole for the beltline trim clip; the small return on the edge of the inner door skin that is angled towards the inside of the door. It looks like it got bent and cracked, which lead to the bigger crack that propagated on the visible part of the inner door skin.
The bend is highlighted by the yellow line. I believe this part is supposed to be flat/straight. Can anyone confirm? If not I will check by referencing the passenger door. The green arrow points toward the crack. With this part broken, vibration goes to work on the crack on the far side of the trim clip hole.