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  View original topic: Doorskin replacement issues
NEPAbeetle Sun Sep 15, 2024 3:34 pm

Cut the existing door skin and unfortunately the panel “popped” in the wrong direction. So now the existing metal is roughly a 1/2” below the new. Am i kind of screwed at this point or is there a way to brace it and weld?

far rider Mon Sep 16, 2024 12:06 pm

Not sure I follow. Cut in the wrong direction? So horizontal not Vertical? Ice versa? Anyway I have a replacement door repair panel (passenger door. ) Youre welcome to it if you want to pay shipping .

bomberbob Tue Sep 17, 2024 7:01 pm

Can you post another photo, but stand back a little bit so we can get the big picture of your question?

NEPAbeetle Fri Sep 20, 2024 3:27 am

Sorry for the confusion. I cut the door lengthwise near the top and the existing panel dove downward under the new panel.


Slow-N-Rusty Fri Sep 20, 2024 12:44 pm

Some simple butt welding clamps should get that aligned while you tack things together.


NEPAbeetle Mon Sep 23, 2024 3:41 pm

Didn’t expect it to come up with the clamps as much as it did but looks like it’ll be okay. Thanks for the tip.


bomberbob Mon Sep 23, 2024 7:05 pm

I did the same thing you did, the door skin had the square door handle hole which was not right for my door. Brazilian door. I cut it below the door handle horizontally, but instead of butt welding edge to edge, I used the flange tool to flange the edge, and then I used panel epoxy to glue the two together. I think the flange added some strength. What you are doing should work fine as long as you don't put too much heat in one spot and cause a warp.




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