First of the Texas Twins, First Build Options

[Puebloswatcop]

I had worked on some of the issues on this door several months ago, but felt it was time to re-inspect it to see what needed serious attention. Here are the improperly aligned holes drilled by a prior owner to mount a passenger side mirror.

[Puebloswatcop]

The door handle mounting area has a crack and will need attention as will the bolt hole for the handle.

[Puebloswatcop]

For the most part the outer door seal channel looked pretty good, until I got to the lower front part of the channel. A small rust hole will require about a 3" area to be excised and replaced.

[Puebloswatcop]

And the patch that I put in long ago, where the PO had chopped it up to add the door mounted spaekers will need some additional attention as well, just some minor trimming and grinding to make it smooth.

[Puebloswatcop]

This photo shows how far off the holes were drilled from where they should be. Who ever drilled the holes, missed the mounting plate completely. I will weld these hole shut and re-drill them where they belong. The black arrows are where the holes should line up, the red arrows show where the PO drilled them.

[Puebloswatcop]

With the inspection finished and a list of repairs to be done, I decided to start stripping the paint from the skin of the door. It had 2 layers of color on it and evidently some other repairs done previously. I used a long board and block sanded the paint, just so I could see how much I would need to do to get the door skin flat. As you can see there are a lot of low spots that will need to be addressed to get the skin nice and flat.

Maybe tomorrow.....

[Puebloswatcop]

Yesterday got cut a bit short, but I was able to get started on the rust hole in the seal channel. I marked out what I believed to be the area that would get me into good metal. But as I went on, there was more that had to be cut. I initially thought the material in the base of the channel was good with just surface rust. I ended up having to cut it out as well.

[Puebloswatcop]

As I was cutting out the damaged area, I failed to notice that my cutting wheel was taking off the top portion of the lip of the channel (IMG:style_emoticons/default/headbang.gif)

But I was able to weld the base of the channel in and repair the lip. Unfortunately the repair of this area is taking longer than I anticipated because of the curvature of the door channel.

[Puebloswatcop]

I started to weld the patch into the lower weather stripping channel and was having a hell of a time getting smooth welds, At first I just thought it was me, trying to get into the channel, but then I checked the welder and discovered I was out of shielding gas.
Its amazing what a difference that makes. But I was able to get the patch welded in. I still want to touch it up a bit, but its in.

[Puebloswatcop]

Then I worked on smoothing out the old frame repair. Of course it was a bit thin in spots and I burned through, but filled the holes back in and built them up, then re-ground them
till I got the result I wanted.

[Puebloswatcop]

I started stripping as much of the old paint off of the inner door frame as I could with a sanding disk and flat sander. most everything from here will have to be done by hand sanding.

[Puebloswatcop]

And back on the outer door skin, a bit more sanding exposed where someone had repaired some door dings prior to re=painting the car. It also has some major low spots in it so I will strip it completely, put a skim coat of filler on it and sand it till I get it as smooth as I can.

[bkrantz]

Something about doors that attracts dings and dents. At least you didn't find an inch of bondo.

[bkrantz]

BTW, if you have not tried a shrinking disk, some shallow door dents might be just the place.

[ClayPerrine]

BTW, if you have not tried a shrinking disk, some shallow door dents might be just the place.

Shrinking metal is a black art. I know I never mastered it. I just pay someone that really knows what they are doing. Motor rebuild... Piece of cake. Transmission rebuild.. no problem. Electrical issues... Easy stuff.


Paint and body... NOPE NOPE NOPE NOPE NOPE.

[Puebloswatcop]

Something about doors that attracts dings and dents. At least you didn't find an inch of bondo.

I feel pretty blessed as to the condition of the doors. I think the deep valley at the leading edge of the door is the typical damage from opoening the door without the limiter installed, but even it isnt as bad as some I've seen. I've never tried the shrinking thing so I may give it a go, just to try it.

[Puebloswatcop]

BTW, if you have not tried a shrinking disk, some shallow door dents might be just the place.

Shrinking metal is a black art. I know I never mastered it. I just pay someone that really knows what they are doing. Motor rebuild... Piece of cake. Transmission rebuild.. no problem. Electrical issues... Easy stuff.


Paint and body... NOPE NOPE NOPE NOPE NOPE.

I hear you there Clay, I have always hated body work, but I promised myself I would give it a go on this car. So far I have actually kind of enjoyed the work since I am retired again. We will see, after this car I may never do it again

[worn]

BTW, if you have not tried a shrinking disk, some shallow door dents might be just the place.

Shrinking metal is a black art. I know I never mastered it. I just pay someone that really knows what they are doing. Motor rebuild... Piece of cake. Transmission rebuild.. no problem. Electrical issues... Easy stuff.


Paint and body... NOPE NOPE NOPE NOPE NOPE.

I hear you there Clay, I have always hated body work, but I promised myself I would give it a go on this car. So far I have actually kind of enjoyed the work since I am retired again. We will see, after this car I may never do it again

It is fun to try new stuff or new angles on old stuff. I had the same rust repair on a door that I thought was in perfect shape. You seem to have mastered the art. I haven’t tried a shrinking disc because I am pretty sure that Clay is correct.

[bkrantz]

Something about doors that attracts dings and dents. At least you didn't find an inch of bondo.

I feel pretty blessed as to the condition of the doors. I think the deep valley at the leading edge of the door is the typical damage from opoening the door without the limiter installed, but even it isnt as bad as some I've seen. I've never tried the shrinking thing so I may give it a go, just to try it.

Try it. I found that on some of the bigger, flatter panels any metal work tended to stretch the sheet metal, and cause a subtle low or high spot that could be reversed but not removed. My shrinking disk use was simple: spin it on the panel to get it warm to hot, and then hit it with cool water from a spray bottle. Some areas took several rounds. Not perfect, but it did help. Worst case it does nothing. And you get to buy another tool.

[friethmiller]

Kevin, I’ve done this in the past with good results. There are some good tutorials out on YouTube. I’m about to do this on my driver side door next weekend. Just need to figure out where I put my shrinking disc. (IMG:style_emoticons/default/idea.gif)