With the tub at the body shop I started work on the doors. I searched everywhere for an early "no-rust" door and I really don't think they exist. So I bought a late no-rust door and used it as a donor and I was amazed at the weight difference between the 2. The late door has to be 15-20 pounds heavier. Luckily the area I needed to replace is identical on both doors as long as I left all of the original holes on the original door.
The rust was extensive in that the metal was completely gone for almost the entire length of the bottom of the door.
Click to view attachmentClick to view attachmentBecause of the contour it's like fitting a 3d puzzle piece into place. Cut, grind, fit, measure, cut, grind, fit, grind , fit, grind, fit....Repeat.
Click to view attachmentI then zapped it into place and took my own sweet time welding it in. Didn't want any metal to move so I would hit it with a few welds and walk away to do something else. If I could touch it and it was cool I'd hit it again and walk away. I have a mental issue when it comes to walking away from an incomplete job and have been known to push the limits on heat while welding only to have a bigger problem then when I started, so this was a major OCD win. Overall I'm happy with the results. It stayed nice and straight and now I just have to break out the grinder and the Dremel for the seal channels and deliver to the body shop.
Click to view attachmentClick to view attachmentI received a call from the painter and over the last 2 days he was able to get 90% of the metal straightened and all of the little dings etc. removed. He thinks he'll shoot high build primer this weekend.