Are the door posts rusted & inner rockers bad, too?
If door posts are not being replaced, then careful drilling out of spot welds
and careful peeling of the outer cowl from the post is in order. This should include
bracing; esp if the floor&inner rocker has been removed or is rusted out completely. Tack the outer,inner,kick panels and trial fit the door to assure yourself that it will align properly.... now is the time!
Judicious sequencing of the cut out of the panels need to be considered so as not to put undo stress on the door posts.
Keep in mind that the floor, toe board, inner kick panels, middle filler panels,
and outer cowl panels all converge... if you cut all away then the body will sway in the breeze!
Lastly, if replacing the toe board then use the radiator support and inner fenders to help guide you as to proper angle before welding and keep the inner fender bolts holes in alignment with your new toe board. IF NOT replacing the toe board then keeping them attached to the toe board and radiator support will help in bracing the body...
My 2 cents
mike
