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As you can see from the picture someone has done a little remodeling. Anyone have any idea what these holes might be for.

Doug

Doug,

Just a really big WAG here, but first thought that comes to my mind is access holes for outer skin dent repair???

Those will be a bit of a challenge to fix, sorry to say.

It sure was nice of the PO to weld the cutouts back into place to maintain the structural integrity of the door.

Well, naturally, those are speed holes…


Oh wait! Shouldn’t those be on the outside?!

Weight-saving holes for a quicker time from stop light to stop light.

Those are weight relieving holes. Drivers door too heavy.
Swiss cheese.

Doug,

Just to get your thread back on track (thanks to the fellow Bolters that offered "alternative" ideas - LOL ), are you intending to save the door and repair to restore to original appearance?

That is possible, but welding in patches is going to be very slow/time consuming if you want to avoid contorting the shape and fit of the door.

Your conversation may better fit in the Paint and Body Shop "Doors" sub-forum depending on what you plan on doing.

Don't know why they were done and I realize you didn't ask how to repair. Here is a suggestion for you or anyone else,

The least expensive way, "easiest" to fix, is find someone (electrician or HVAC) with a Greenlee type hole punch the same size that was used. Make round patches and weld slowly, one at a time. The indent portion of some patches can be made with round stock as a mandrel. Use a large piece of metal and a rod, indent a long dimple in it, same size and depth as door dimples. Then punch out each. Locate punch on dimple to duplicate each hole patch. Work each patch a little after punching out until good fit. Use this as a brainstorm for your own method as you see fit.

I don't advise a big skin patch from a vendor or donor door unless it's used as punchout material. It is a method some will like. It has a slight warp risk to do that. If you don't have a welder, buy a donor door and transfer all hardware....but that will have it's own can of worms. If you can do the weld repair without removing door, that is way less work than to realign door. Spot welding does not need to lay flat.

A round hole has less impact on structure usually. No worry to leave alone unless oil canning/noise.

A round patch has no stress corners and easier to weld in. looks like only about four need a dimple. One hole will be covered by a panel.
There are various inner cowl panels available that may have the same dimple. They may be a good head start for punchout patches.... or of course, as said, a door skin.

What bartamos said. It might be less intrusive to the structure if you made the patches a little bigger than the holes and used panel bond to attach them to the back of the door panel, and then fill and shape with filler.
If you can dig up a donor door (one that's rusted out on the outer skin or beat up would work, as long as that rear half of the inner skin is in good shape,) it might be less work to cut a patch incorporating all those holes instead of patching each separately. This might be a spot where a lapped joint, either welded or bonded would be appropriate. Using aflanging tool would help make the job go easier.
Unfortunately, that topmost hole isn't entirely covered by the upper door panel that's screwed in place. Nice of them to overlap it. If they hadn't you could leave the hole there.

Good Luck

I may look at getting a replacement door since the only thing installed right now is the door latch.

Doug

There are custom door panel covers available which cover the entire inside of the door.

Maybe this will help. . Just a place to go for parts. I have bought from them and my only complaint id the shipping is a little steep.