Need some door help..

[62step]

I tried to go the cheap route on my doors and it was a mistake.. I tried to weld some sheet metal in instead of panel the patch panel, I wanted to get it done quick and it's now warped almost half way up the door. It's very embarassing so I won't post pictures, so..

Should I drill all the spot welds out around the bottom and buy a inner door skin and outer door skin to try and fix it the right way? Or is there another route? Buy a new door (I cna't find any manufacture that makes new 60-62 doors), I guess I'll have to go with used if I choose this route.

Maybe once I cut this crap out I might post them. I'm just afraid I ruined the entire door because I let too much heat in one spot. Thanks for any advice!

Mike

[65sub]

post some pictures of what you have. every body makes mistakes. it's no big deal. your warpage may be relieved once you cut out the welded area. also a description of your welding technique might show what you can change

[62step]

I will once I get home from work. I'm using a harbor freight flux core welder, that might be the problem, or it's me, but I know I stayed in one spot too long.

[Sledgebone]

Don't try to run a bead. Keep making small weld dots, and jump around on the panel to keep from building up heat. It is a long and tedious process.

[62step]

Here are some pictures... Like I said I'm not a pro, first time doing this stuff...



This one I took some welding wire to show the extensive warp

Here's the rust on the other side of the patch.

[61_FL_Apache]

Originally Posted by Sledgebone

Don't try to run a bead. Keep making small weld dots, and jump around on the panel to keep from building up heat. It is a long and tedious process.

This method works best.

[T.W.Dustin]

Maybe find another door? May be the easiest route for you. Of course I am in AZ so maybe there are more options here for low-rust parts but it saves a ton of time.

[62step]

Yeah, I was thinking a new door route too, what should I do about the other side? Find another one also or let a professional do it?

Thanks for replies.

[63burban]

Thats what they make Bondo for, mud er up

[62step]

I told my wife when I got done, "honey, that thing is going to need a whole lot of bondo." She just rolled her eyes.

[Monte's62]

Please don't fill that with mud. I think 63burban is kidding....I hope.

[62step]

I was going to fill the spot with the patch to smooth it out until the warpage happened. Then I came here to get some advise, but I guess my best bet is to get some new doors.

[63burban]

Really, I would take it to a local body shop and see if they can straighten it out, might cost the price of a door but those doors look pretty decent.

[62step]

They are pretty decent, only rust are the spots I posted. We really only have Maaco and some other body shop that has a lot of cars with 24's and 30" rims and crown vics and such, don't really want to use them, hopefully can find a pretty local shop. Thanks for the advice.

[65sub]

Try cutting out the patch that you welded in. Nothing to lose now but maybe you can still save it. Cut about 1/2" larger and see if the warpage smooths out. If that works weld the new patch one small dot at a time. use your hand as a gauge, if you can't put your hand on the weld wait before you continue. Don't try to speed up the cooling with water or compressed air. Grind the weld dot down close to the surface before you overlap the next. Be patient' it takes a lot of time.

[62step]

Thank you! I will try to cut the patch out and see if that helps, For the other side (inside the dioor) at the bottom, will I have to drill out the spot welds on the flap and replace that corner to get rid of all the rust on that corner?

[racecougar]

That door is very savable. Cut that patch back out, bump the panel back into shape, and take your time when you weld the patch panel back in. If you're able to back up the tacks with a dolly, tack, planish, grind, repeat.

For the inside lower corner, open the seams, cut out the rot, weld in your patch, fold the skin back over, and plug.

You're in great shape compared to the turd of a door I just "polished".

[ljackson]

Lots of good info here for welding and working sheet metal. I learned a lot from this thread.

http://67-72chevytrucks.com/vboard/s...d.php?t=564201

[67swb72klb]

Originally Posted by ljackson

Lots of good info here for welding and working sheet metal. I learned a lot from this thread.

http://67-72chevytrucks.com/vboard/s...d.php?t=564201

Yep the guy knows how to work some metal!..
The flux core is not too good for sheet metal work But you should be able to save the door.
The biggest thing is taking your time