Question on replacing inner and outer door bottoms

[Hart_Rod]

I'm fixing a set of doors for a friend (they look like swiss cheese at the bottom) and I'm trying to figure out the best way to do it. I tried the search function but didn't really see anything that helped. My biggest question is, which part do you replace first - inner or outer? Thanks in advance.

Rob

[raggedjim]

Rob, good question, I have been looking at mine and was wondering the same thing.

Rg

[67ChevyRedneck]

Never done this before, but thought about it.... I would probably replace the inner first. Peel back the skin on the door where the inner will be replaced and modify the new inner if need be. The outer should then fit (hopefully) nicely over the new door bottom.

my 2 cents

[RustyParts]

If you have the Tristar replacement panels take some really good measurements before you cut off anything, because they're not quite the same as the original door.

I cut out the inner door first and started from there.

I guess the hardest part was trying to cut and fit the inner piece as to maintain the original curvature of the door and not have a lot of big gaps to weld up.

Also use a bead of sealant around the door bottom when you put the outer door skin on.

Also bend the door skin outer flange slow and in small steps to keep from warping it.

If I had it to do over, I would have bought the complete door.

[67ChevyRedneck]

Originally Posted by RustyParts

Also use a bead of sealant around the door bottom when you put the outer door skin on.

Wow, great work on putting the doors back together!

Do you have any drain holes on the door bottoms? Factory doors have two drain holes, without them you're doors will rot pretty quickly. If they're there, sweet, if not, just givin' ya a "heads up."

[RustyParts]

Originally Posted by 67ChevyRedneck

Wow, great work on putting the doors back together!

Do you have any drain holes on the door bottoms? Factory doors have two drain holes, without them you're doors will rot pretty quickly. If they're there, sweet, if not, just givin' ya a "heads up."

Yeah I did those last, I forgot to put some in my old 40 olds when I did the doors on it. A big rain caught us outside at a car show and when I opened the doors they sloshed.

[raggedjim]

Rusty, you did a great job, but you are right, it looks like a lot of work...

Rg

[Hart_Rod]

"If you have the Tristar replacement panels take some really good measurements before you cut off anything, because they're not quite the same as the original door.

I cut out the inner door first and started from there.

I guess the hardest part was trying to cut and fit the inner piece as to maintain the original curvature of the door and not have a lot of big gaps to weld up.

Also use a bead of sealant around the door bottom when you put the outer door skin on.

Also bend the door skin outer flange slow and in small steps to keep from warping it.

If I had it to do over, I would have bought the complete door."

Thanks for the info Rusty. I agree about buying new doors, however, my buddy didn't have the cash to buy new ones, $500 vs $75 (he has a 66) was the determining factor.

[Botietruck]

I replaced my inner & outer door bottoms, but I cut about 5" out, just enough to get rid of the rust. Before I started cutting the old metal out, I took several measurements and put everything back to those dimensions. Everything fitted up well and I did cut drain holes in the bottom, as close to the originals as possible. All in all they turned out very well and I'm glad I did it, but it was a lot of work.
While I had the bottoms open, I sandblasted, etched and epoxy primed the inside of the doors. Then I sealed the seams with 3-M seam sealer. I then sprayed a coat of Gravitex on the insides of the doors after they were completed.
The reward came when i fitted them up and they fit perfectly.

[Hart_Rod]

Just wanted to thank everyone for all the tips. Here's what I got done in about 2 hours tonight. I got the inner tacked in and the outer fitted with the door on the truck. Figured that was the best way to make the body lines match. Just a little more cutting and then it all can be welded up. This was the worst door, hopefully other side will go as quick.

[69TowRig]

Great work!

[meathead95]

i did mine the same way it was fairly easy.