Holy poooooo
 

So I finally got everything out of the door and cleaned out the bottom and this is what I find. Ok, in all fairness I am sure it does not come as a surprise that there's a big hole in the bottom of the door but still. I am curious is it possibleto just cut out the hole/bottom of the pan and weld in a patch (I have plenty of extra metal as I am pulling the metal from the pickup bed that someone installed). Or should I buy something like this http://www.rockauto.com/catalog/more...432&cc=1324280 has anyone used this patch from rockauto? Seems a bit overkill for what I need but that being said I am asking a higher power (the forum). All that being said I found the loud clanking sound coming from the driver door, apparently the old window mechanism fell off and they just left it down there HA

Re: Holy poooooo
 

I don't know anything about the quality of the patch panels that Rock Auto sells, but you don't have to use the whole thing. Just cut as much of your rusted area needed to get to good solid metal. Then cut a section of the patch panel to fit the opening and weld in place.

Re: Holy poooooo
 

Yeah but especially since all the rust is just on the flat bottom I think I may just weld some metal in there and not even worry about the patch.

Re: Holy poooooo
 

if it is just on the bottom and flat and you have good metal left around it just get some sheet the same thickness and go for it

Re: Holy poooooo
 

Like Captain fab said you got to cut till you find god metal to weld to. The hole may end up pretty big. Also that patch panel allows you to cut back to the door skin lip and have a piece that will be easier to match to the curves in that corner.
Jimmy