Door stay area too damaged for repair kit 911 SC

[Rodek]

Folks, I'm at the point of repairing my door stays on my 1978 911 SC. I have an issue though. The door stay area has been completely ripped out so much so that the door stay repair kit will not work. My mechanic and I have come to the conclusion that we must either cut the damaged section of the door out and then weld in some sort of fabricated metal plate to reinforce the area well enough to allow the installation of the door stay. I unfortunately do not have a picture handy but sincerely request info from anyone who has had to fabricate something because the door stay repair kit wasn't adequate enough for the job.

[john walker's workshop]

Sometimes you need to open an access hole in the inner door panel with an air saw to do the larger repair, which is butt welded up in the end. Make a sheet metal panel which can fit inside the door skin to protect the skin from heat/paint damage and fab what you need to git 'er done. Mig weld slow and keep the heat down.

[Rodek]

Originally Posted by john walker's workshop

Sometimes you need to open an access hole in the inner door panel with an air saw to do the larger repair, which is butt welded up in the end. Make a sheet metal panel which can fit inside the door skin to protect the skin from heat/paint damage and fab what you need to git 'er done. Mig weld slow and keep the heat down.

Thank you for taking the time to respond. This makes sense! We'll look it over again and give it a go.

[Brandonmel85]

Couldn’t you technically just weld the reinforcement kit to the door?

[Hulley]

Originally Posted by Brandonmel85

Couldn’t you technically just weld the reinforcement kit to the door?

I can't speak for the OP but I'm in a similar position, the damaged area is larger than the repair kit so the repair kit doesn't have anything to hold onto. The repair kit sandwiches the area with weakened metal, or at least the repair kits I've seen.