Lower door patch panels

[samples45]

I got the inner and outer patch panels for my driver door. I've read on here where some guys replaces one side first then the other, my question is what's the best way to do this fix when the inner and outer are not attached?

[_Ogre]

make a hardboard template of the front and back edges of the door
i used cardboard and had mixed results

pass door is fine



drivers door could have been better

[Russell Ashley]

I made my templates out of 3/16 inch plywood. Also, I made my templates to match the shape of the cab just at the door opening edge as that's where I wanted the door to match.

[dwcsr]

Originally Posted by Russell Ashley

I made my templates out of 3/16 inch plywood. Also, I made my templates to match the shape of the cab just at the door opening edge as that's where I wanted the door to match.

This is the best way as the doors are not the same in the front curve as in the back curve , the doors actually taper front to back and curve differently top to bottom. I use a jig when its inner and outer replacement. 1/2 pine for the curved pieces and they are screwed to a plywood base. Then just lay the door into it, fit and tack up the outer, then fit the inner and tack it up, then try it on the cab. You need two jigs, left and right.

[samples45]

Originally Posted by dwcsr

This is the best way as the doors are not the same in the front curve as in the back curve , the doors actually taper front to back and curve differently top to bottom. I use a jig when its inner and outer replacement. 1/2 pine for the curved pieces and they are screwed to a plywood base. Then just lay the door into it, fit and tack up the outer, then fit the inner and tack it up, then try it on the cab. You need two jigs, left and right.

Do you happen to have any pictures of the set up?

[samples45]

Thanks guys! My thought was putting the door on the truck and cutting the outer off and tack welding the new outer skin on while the door was on the cab to get the right angle and then taking it off and finish it.. not sure how that would go though! any thoughts?

[dsraven]

remember to fix the lower hinge mount while the skin is off. also check the area in the window opening where the vent window goes into the door, lots of doors crack there so the inner and outer have a bunch of flex. hard to get the door to fit right if it is flexxie.

[samples45]

Originally Posted by dsraven

remember to fix the lower hinge mount while the skin is off. also check the area in the window opening where the vent window goes into the door, lots of doors crack there so the inner and outer have a bunch of flex. hard to get the door to fit right if it is flexxie.

im goin to replace the lower hinge mount also! and thanks ill check mine out!

[Clarance J]

Hey Samples45.Here is something that might help locate the lower hinge pocket in relation to the upper hinge pocket. I used 2x1/4 flat stock to make copies of the ends of the hinge both upper and lower an and tacked a bar between them. The cab side of the hinge should be bolted in the center of its travel for adjustment . After tacking check fixture on the door. New or repaired pockets can be installed this way without worry about being located wrong. It worked for me.

Earl