It has been a very busy last two days. I have been working in rebuilding the left door. In my last update I posted the repairs to the inside door bottom. Yesterday afternoon I went ahead and cut off the outer skin. This door had a lot of hidden damage. The inner front hinge side was pretty well bent up. I was able to get everything back to where I believe they should be.
With that repaired, I moved on to the lower hinge bracket. This part is not that accurate. The two small tack welds holding nuts for the hinge on were way too little. I am sure that they would have broken off very easily. Ti was also not bent or assembled correctly. I ended up cutting the 5 spot welds that held the two parts together and moved it to where it should be. I tacked the bracket in place and then mounted the door on the truck. Once I was sure that the bracket was OK, I welded it up fully. I then mounted it again. It turned out that the replacement cage nut that I installed for the upper left top hinge bolt was not going to work. In a previous post, I mentioned that this cage nut only allows 1/8" vs 1/4" adjustments. Kevin drilled out the welds and cleaned it up and moved it further out. We reinstalled the door and checked the fit. The fit is much better. Kevin then painted the inside of the door as well as the inside of the new outer skin.
I then started fitting up the new skin. I have it measured up, and it is the correct measurements. I then fit up the drain holes and welded the new skin on. I called it a day. 9 hours is enough! I only have a few photos to post today.
Tomorrow I will post some photos of the outer repair.
