Thanks 962: Could you advise me on the specific door mentioned above?
The door was true & flush with no damage, but it had started to rust through in a few spots along the bottom seam. The vertical sections showed signs of rust migration, so I ground just enough of the seam to allow a gap. The door was acid dipped totally clean. I then MIG welded along the outer edge of the seam. Unfortunately, the door then sat for 20+ years coated only in oil spray. I’ve removed the external rust but there’s still surface rust on the inside. Below are some pictures:
Can you recommend how best to proceed? I don’t want to leave the possibility of future rust along the seam. I can think of three options: 1. Grind, re-strip the door & weld it again or, 2. Cut the lower section away, re-strip & splice in a new lower section or, 3. Fit a complete skin. I’m leaning towards the first option since I think there’s a better chance of maintaining the correct gaps. Also, I’ve never skinned a door. Do you think welding the length of the door seam will be durable? Driver’s doors see much more use that the passenger door. The plan is to Epoxy coat the door throughout including the seams.
I’d appreciate any advice,
Charles
