How do I fix cracked metal door panel?

[Pick121]

Found this cracked metal around the window regulator, after removing door panel to fix door latch. I could just close it up and pretend I never saw it...but that’s not my style! It does not affect window crank operation “yet” but it looks like it will just get worse. Any ideas how to fix it? Or vote to just leave it alone?
This is my ‘64 C10 fleetside

[The Rocknrod]

Cut the damaged section out and weld a new one (or undamaged) in.

[ACK]

2nd that on cut and patch. If this is a fix for down the road, drill a hole at the end of each crack line to help prevent them from spreading further. Drilling isn't the cure, it just stops their growth for a bit.

[61hawk]

Makes you wonder what the story is behind those cracks. They're stress cracks, but how were they caused? Was the window that hard to open and close that over years it finally cracked? Were the screws loose which caused flexing of the metal in that area over a long period of time?

Since it's covered up I'd weld it up, put the cover back over the door and forget about it. If I were doing a full restoration I'd cut it out and replace it.

[SkinnyG]

My '61 had cracks at the window guide mounting holes at the back jamb of the door. Cut 'em and patch em and move on

[pdxhall]

I looks to me like you've got a rust problem that has gotten so thin that the normal window cranking pressure has caused it to crack through. you might be chasing a bigger problem. If you could find a donor piece that you can patch in would, in my opinion, be the best wat to go unless you're an excellent metal worker.

[SkinnyG]

I would disagree - they look like fatigue cracks to me.

Had them at the West Coast Mirror mounts, the window guide mounts, and the window crank mounts on one door. I'll bet the later trucks have either larger fasteners or thicker reinforcements.

[cwcarpenter98]

That hole beneath the bottom screw should not be there. If I had a scrap door, I'd cut that section out and send it to ya, but unfortunately, I don't have a scrap door

[Riverstory]

Or create a plate that fits inside the recessed part of the door, drill a couple of holes then weld the plate to the door. New support carried on either side of the cracked area.

[AcampoDave]

For a "gitterdone" kind of fix...maybe weld some appropriately sized washers on there.

[Getter-Done]

Lot of Great Idea's above

I will add, Which ever route you choose,

When welding like that
It is best to use some type of copper backing plate or spoon.

Here is a video to explain more.

Link: https://www.youtube.com/watch?v=PAKH0QAfv_A










.

[franken]

I'd just weld up the cracks and butt weld a patch in for the missing bit. Maybe anneal the area afterward.
Check it in 20 years to make sure it's still ok...

[Pick121]

Thanks for all the reply’s friends, lots of great ideas & input. I will probably go with welding in a patch. It is a daily driver not a show truck. It seems like a real fragile area to weld between the bolt holes and with a chunk of metal completely missing. Also some of the other ideas I am concerned how it will affect the alignment/operation of the window regulator. As this is my first try at welding in my 57 years on this rock I am glad it will be hidden behind the door panel when it’s done!
I agree about the stress crack as cause, the window “does” roll up & down but it is takes some muscle, not smooth like butter that’s for sure - and no major body rot inside the door panel. The reason I found it is because this is one of those trucks that whenever I shut the door, to get out I had to roll down the window to open the door with outside door handle (inside door handle did not work the latch). Which is why I am replacing the latch. Been this way since I got it and finally got tired of rolling the window down and then up again to get out! So, thanks again for all the advice

[AcampoDave]

Have you sprayed that coil spring really well with something like PB blaster? Spray it and keep running the window up and down, spray it again and repeat....and just keep doing it while you watch the rusty crap roll outta there and run down the door. It will smooth things out.

[SkinnyG]

On my door with the most cracks, the spring was broken.