Door Speaker Hole Repair

[JGross]

I'm sure I'm not the first to make this repair but it turned out so good I wanted to share it with you. I have 0 body working skills so if I can do this anyone can.

This is the passengers side door on my 65 C10 project.




I cut the hole square because it is easier for me to make a square using a cutoff wheel than a circle. ( While I had the bottom of the door open I put in the sound deadening mat. I also found that there is a support brace inside the door if you go much further forward.





I used the bottom off a doner door that was rusted beyond repair.




I used the back end of the doner door to replace the front end of my project door. The panel reliefs will match up you just have to make sure that you find the center line of both relief panels and that measure back on the doner panel the same distance as the leading edge of the hole on the project door.



It took a little sanding to get a good fit and I use these leveling tools I got for Eastwood to match the patch to the door.



I used a Mig welder to weld out the patch



A thin coat of body filler to smooth everything out



and some primer and spray paint and ALMOST like new