A quick up-date (while I remember),
I thought I'd get away with 2 corner repairs on the outer skin but it turned out much worse than I thought and ended up replacing the whole lower section. Doing the outer skin in 2 halves is not the most efficient way but hey-ho.
Once everything was tacked in place I hung the door back on the cab to check alignment and fit (I forgot to take a photo) and the fit was really good. Once happy with the fit I fully welded the inner.
I had weld the outer skin a little at a time, as the welds cooled and contracted they pulled the skin inwards making the skin concave and creating a hollow. So it was weld a little, hammer and dolly back out weld repeat until done. The access to the rear of the door skin is really restricted, you have to wedge your arm through the larger hole at the top. If only my arm was a foot longer and I had an extra elbow I might have avoided this bruise
the sacrifices we make for our trucks
The outer skin still needs a little work but the shape is 95% there
