Door repair question

[Matthewjb]

Hey guys I have a question regarding rust on doors. I'm a novice at bodywork and wanted to get y'all's opinion on how to fix. The doors are in great shape other than some rust on the bottom, right on the bottom where the doors begin to curve up.

[72bowtiestepper]

Originally Posted by Matthewjb

Hey guys I have a question regarding rust on doors. I'm a novice at bodywork and wanted to get y'all's opinion on how to fix. The doors are in great shape other than some rust on the bottom, right on the bottom where the doors begin to curve up.

A pic or 2 would help us see where the rust is & give you advise how to repair. Door skins are avail. from the aftermarket to repair rust , as well as bottom of the inside of the door patches. Don't just throw bondo on the holes...the rust must all be cut out or you will be doing the same repairs over & over......not fun at all.

[burnin oil]

Without even looking at them I will tell you this from experience. Plan on alot of patch panel work. The doors rust from the inside out because dirt and leaves plug up the drain holes at the bottom of the door. What looks minor will actually be to thin to weld. I just went through this when reworking my doors. Looked good until you try and weld to it and it blew through like it was tin foil! If you sand blast it there will be alot more holes also.

[Matthewjb]

Here are some pics. Sorry about that. This is both of the doors.

[burnin oil]

Plan to replace everything below about 1" up from the bottom inside part of the door. While you are having fun it is a good idea to reinforce behind the door hinges.

[Matthewjb]

Other than this doors are in pretty fair shape

[Mike's money pit]

I think board member ebfabman sells videos covering common rust repairs on our trucks. I have not seen the videos yet (I intend to buy them at some point) but I read somewhere they include repairing doors. Maybe someone can chime in who knows for sure. Here is a link to the videos: http://ebfabman.com/id27.htm

Mike

[Molberg]

https://www.youtube.com/watch?v=YurQpXIdWM4
i stumbled across this while fighting with my doors... he makes some great points to observe if you're going to cut out the complete tub.

[Matthewjb]

Thanks for the info guys, I'm debating on wether or no it would be worth it just to buy after market doors. Im not sure how much $$ I would sing into buying all components and the shell...anyone have a rough guess on that?

[Molberg]

I've heard some horror stories about after market doors. Rep at LMC told me they're "hit and miss". Hit in spots and miss in others. May have to drill spot welds on upper window frame to re-align. Wow. I found some decent factory doors at local scrap yard that required minor repair to corners of door skin vs entire tub.

[In The Ten Ring]

I'm fearful of many aftermarket parts, I'd spend the extra money and effort to get original doors from say NM, CA, or AZ.

[72bowtiestepper]

Originally Posted by Matthewjb

Here are some pics. Sorry about that. This is both of the doors. Attachment 1181866

Attachment 1181867

Those doors are not too bad....a lot better than mine were. If you have a mig welder & some basic bodyworking tools, try to do the repairs yourself...it's not really that hard. Use the utube vid. as your guide...it is very informative.I agree with others about the aftermarket door shells....keep as much of your stock GM doors as possible....Just my opinion.

[Lattimer]

My doors were about the same but also rusted through both corners of the outer skin. I spent about $80 on the patch panels and the body shop is charging me $450 per door to do the repair. That is bring them the truck, they do the repair and paint, hang and realign the doors. One is done and they are in progress on the other now.

So call it $1000 for the repair.

[72bowtiestepper]

Originally Posted by Lattimer

My doors were about the same but also rusted through both corners of the outer skin. I spent about $80 on the patch panels and the body shop is charging me $450 per door to do the repair. That is bring them the truck, they do the repair and paint, hang and realign the doors. One is done and they are in progress on the other now.

So call it $1000 for the repair.

Good bodywork is NOT cheap....that's why I do my own....takes a lot of time to do it right, but I'm in no hurry. You do get a lot of satisfaction when it's finally done though !

[burnin oil]

As others have told you. A little practice and patience with a few basic tools (welder and body hammer set) will reward you with divedinds. The biggest trick is learning to replace a decent amount past the rust with out being tempted to replace the entire panel. In other words you learn to cut up a perfectly good patch panel so that you are only replacing whats needed.

[ebfabman]

Here is 6 hours of door repair in about 4 and a half minutes. Hope it helps.

door repair.wmv - YouTube

[72bowtiestepper]

That's a great vid. Thanks for posting it ! Wish I could work that fast !

[mcbassin]

Originally Posted by ebfabman

Here is 6 hours of door repair in about 4 and a half minutes. Hope it helps.

What a STUD! You make that repair look easy. Thank you for sharing it..... I'm pretty sure the average guy would spend much more than 6 hours. I know I worked on one of my doors for over a week every day after work. I only replaced the lower section not the outer skin.

[motorcritter]

Sitting at the feet of a master! I just might give it a try- good doors are hard to find, and not really cheap when found.

[engineer_gregh]

Subscribed. Great thread

[RaceAGMC]

Originally Posted by ebfabman

Here is 6 hours of door repair in about 4 and a half minutes. Hope it helps.



door repair.wmv - YouTube

Is that you doing the repair?

[ebfabman]

Me?.......Yes, but no remarks about the bald spot.......

[RaceAGMC]

Originally Posted by ebfabman

Me?.......Yes, but no remarks about the bald spot.......

Oh no. Nothing like that, I've got a bald spot myself. I was just asking cause you are a local guy. It looks like I could learn something from you. Do you go to any shows?

[ebfabman]

Just kiddin.....I don't have a bald spot...hahaha.......I'm in Concord near the speedway.

[brans72]

You can find used doors on Craigslist. I would buy used before a aftermarket door.