The door look like it had a HVO (high velocity opening).
And was badly repaired.
Same goes for the bottom. I think I am being optimistic with the size of the cut. Suspect most of the leading edge will have to come out, but I'll try and break it into small bits to try and keep the shape the door intact.
The front edge stands proud of the rocker by 10mm or so. Mostly as a result of the bad patch. The rest of the door gaps are pretty good and consistent.
Almost ready to weld in the outer rocker.
Everything primed, fitted (perhaps a thousand times) and top coated where it'll be hidden from sunlight.
Still amazed how rough welded steel cleans up when it has been ground down and primed. Looks mildly presentable!
Cleanliness next to godliness. Degreaser a virtual component of the surface prep routine. Use in a well-ventilated area.....just saying.
The inner sill with fresh kidney. Finally all welded up and ready.
Small crevice needs attention...welding along edges....
