Inner door bottom replacement

[flyboy2610]

I wish to replace the inner door bottom to repair some rust through issues, and to gain experience so when I do the drivers door (the one that really matters) I will know how to do it properly.
Has any one ever used new patch panels for this? I got some from LMC and wish to install them. Here is the door and the panel:


The original door has the bottom part depressed, as you can see from the pics:



The replacement panel does not have this depression.


If I cut the door to match the panel, I lose that depression. If I cut the panel shorter, to save the depression, then I have compound areas at the front of the door to try to match up.


I know the first step is to grind the outer door skin flange off the door, and separate the two parts.


But then how do I cut the panel or door? What would some of you more experienced sheet metal fixers do?
After the inner bottom is replaced, I plan to do the lower outer skin, so I'll get that flange back.

[67mann]

You call that door rusty The door process was my last project before(C my project thread)my life got to busy to work on it.
If it were me doing this....I would cut your door an inch lower than the depresion and stop were the door roll's.Cut down the edge to the next contour and the cut out the bottom of the door. Reverse that cut on the replacment panel....so you only have the flat part to fit. I would also flange that seam and lap weld it. A cut off wheel on a grinder will be your best cutting tool. In all honesty...I would never waste my time on outer(replacements that is)panels again. PITA to work with...not formed right from the start. Maybe just the lower piece will be fine,but the whole skin replacement

Hope this helps or aleast give's you some direction.....and here's the pg(about half way down)of what I have to work with
http://fordification.com/forum/viewtopi ... &start=225

[undertakerman]

I agree with 67mann. What you show isn't rust meaning it is rust but not RUST! And you don't have to replace the whole door skin or the entire inner door bottom either. Here's my worth on the subject. I will show you RUST on the bottom of the doors inside and out on my attachments.

STEP ONE: First I would strip the entire door of paint and primer down to the metal.

STEP TWO: Then sandblast the areas that show rust. This way you are able to see what you need to do and how much you are going to have to replace.

STEP THREE: Now. Like on the outside corners. Since you have a full outer door skin panel, cut a 10 inch square patch panel off of both corners and cut that same size panel off the door corners.

STEP FOUR: Now the inner door bottom panel. For the front of the door. Cut the length the same as the height of the patch panel and on the rear cut the length 4 inches longer than the angled offset and leave the height as it is. Cut the door bottom the same.

STEP FIVE: Now all you have to do is tack weld the new panels in place and check for fit up and alignment and a square fit.

STEP SIX: If everything is good, weld, grind and use good body filler, sand, treat sandblasted rust areas with a rust enabler and prime.

STEP SEVEN: When everything complete. Spray a rubberized undercoat that you can get at any auto store inside the entire bottom of the door and up the side about 6 inches and make sure you get it down good in the corners.

This is what I have done in the pass and it works great. Well that's my worth .Best of luck to you on your project.

[undertakerman]

Hey Guys. I'm sorry I forgot to do the attachments. Now this is door RUST. As you can see from these 3 attachments, this is RUST. The rest of the door corners inside and out are the same way. The rest of the rust can be taken care of by sandblasting and applying a good liquid rust enabler such as "The Right Stuff Rust Enabler" which you can buy at any auto parts store. You apply it, let it dry over night and it will turn either black or gray and will hard to the touch. Then all you have to do is prime over it and you're finished. Again I wish you the best with your project and all future projects.