So I know doors are available everywhere and there are more rust free tubs out there but that is not the point of my project.. As many of you know I teach welding and fabrication at a local college.. I had a student that is talented but not the most driven in class so I found a way to engage him and show him a skill he will be able to use for years to come..

Here are some pictures of the project

This the progress we made on it in a couple of hours.. My student was so excited to learn how to do this properly

I sand blasted the door inside and out previous to cutting out the former bad repair. The old repair was a lap weld of the wrong thickness steel. And then the upper part of the door was also perforated so that also got a new piece of steel.. I will update pictures Monday.. I now have the door primed inside and out in epoxy primer.. And here is a quick picture of the car

How many rusty doors did you have?
Saw loads of thread...


Seems like a great project to teach on, what state are you in?

Sorry forum issues on the other threads.. . I am in Wisconsin

Here the door is epoxy primed and ready for body work.

Looks like he earned some extra credit. Good work.

He learned allot and hopefully a skill he can use down the road