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I'm ordering a gas conversion kit so I can start welding on my truck. The first thing I want to repair is a door. I will replace the lower door skin and the inner door bottom. Aside from an angle grinder and clamps, what other tools will be good to have?

A couple of suggestions...

I use a die grinder and a 1/32" cut off wheel to cut odd shaped sheet metal. It is faster, lighter and easier to use than a angle grinder.

You will also need some flattened copper pipe to back your welds.

I also use weld through primer on the inside of panels, if I will not be able to access it after it is in place.

Took me a bit to figure a die grinder translates to Dremel tool. Good thing I already have those disks you refer to. I'm going to buy a copper backing tool or pipe for the panel welding. Thanks for the tips. WHat about a seamer for folding the metal over the door edge?

Not really. A die grinder is usually a pneumatic took much like a Dremel but a LOT beefier.
HERE'S A PHOTO of what they're referring to.

Dremel tools are great for light suff but not cutting sheetmetal patches.

'nother misnomer - what you need is a sheet metal brake to pre-fold the edge of the patch piece - or do it by hand starting the bend over a hard straight edge with a hammer

Bill

The door bottom panel I have already has the edges bent. They are just at a 90 degree angle. I'll need something to bend them over the edge of the new door bottom to create the seam. Also, when cleaning up the edges so I can butt weld the pieces together, what works to remove the rust (my door is basically pitted and painted with rust)? How about the protective primer on the new door piece?

Thanks for the tool pictures. I don't have an air supply to push something like that. I'm pretty much restricted to something that'll plug in.

use a small electric angle grinder with a zip disc [thin] to clean things, also use a phosphoric acid wash to neutralize whats left in deep pits ... use wide mouth vise grips on the edge bend, crimp it down a bit at a time ... spray the existing edge first with high zinc primer [cold galvanize paint], also the back of the piece you crimp over it ... use epoxy primer on the finished work if you can

Bill

I'm going to have to find a small angle grinder. I have a DeWalt angle grinder with an angled flap wheel sander but I don't know if that's too much. I like the vise grips. I'll get some of those as soon as I can. Is the high zinc paint something that can be welded through? Do I need to weld the metal that I crimp over?

the crimp doesn't need more than tack welding, that's all the factory did and little of it - some of the zinc paint is called 'weld-thru primer', so yes, but avoid breathing the fumes!

the flap wheel is 'not enough' - good for many cleaning chores, but getting to clean metal for welding a grinding wheel is best, should be easy to find the mount to put one on the DeWalt like this

for doing metal work you can never have enough vise grips, welding clamp style and various size C clamp type especially

Bill

That's the grinder I have. I'll be using that to do some clean up. I also have that particular grinding wheel that's in the photo. I guess I'll make sure I have my camera handy to document the door. I'll make sure I have plenty of ventilation when I weld. Thanks for the tips.