Here we are filing off flashing left by the die grinder.ġ6. Care needs to be taken so that the underside of the metal is clean and won't hold the backing strip away from the new metal. Since the metal strip needs to be fastened FLAT against the inside of the metal it's best to punch and not drill since drilling causes the metal to dimple and hold the metal away.ġ5. Holes are punched along the edge of the remaining door panel. We'll be using both pieces since the strip we cut off can also be used as a backing strip.ġ4. Here the new metal is shown after the cut. This time we cut with an electric shear because it makes a nice straight cut that is very clean on both sides.ġ3. Again a piece of tape can be placed on the metal to mark a straight line for cutting or you could mark it with a pencil.ġ2.
The new metal is place so that it's aligned properly then marked to cut for butt welding.ġ1. Preformed door bottoms are a standard repair part for this type of repair. After the jamb metal is exposed it should be sanded to remove lose rust then treated with a rust converter one the edge of the jamb and also inside the door.ĩ. In many cases this can be done by prying the strip off the jamb metal but in some cases it needs to be ground or drilled to prevent damage to the jamb.ħ.& 8. The door is now flipped over and the remains of the outer panel are removed. You can see how grinding the edge releases the metal we want to remove.Ħ. After the top cut we grind the bottom and side edges to release the panel.ĥ. You can see, after the tape is removed, that we have a nice straight cut.Ĥ. We can get fairly accurate and straight cuts using this method.ģ.
We do most of this type of cutting with a small angle grinder and a good cut-off disk. We've taped a straight line just below the peak to guide a nice straight cut.Ģ. This is the exterior of a truck door that has be ground down to reveal major rust problems.
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