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NEPAbeetle
Samba Member
Joined: August 02, 2018
Posts: 23
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 Posted: Sun Sep 15, 2024 3:34 pm Post subject: Doorskin replacement issues |
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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?
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far rider 
Samba Member
Joined: August 30, 2005
Posts: 900
Location: Rutland, VT
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| Posted: Mon Sep 16, 2024 12:06 pm Post subject: Re: Doorskin replacement issues |
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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 .
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67 zenith blue sunroof
Contentment; when what you have is what you want. |
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bomberbob
Samba Member
Joined: May 17, 2015
Posts: 728
Location: Iowa
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| Posted: Tue Sep 17, 2024 7:01 pm Post subject: Re: Doorskin replacement issues |
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Can you post another photo, but stand back a little bit so we can get the big picture of your question?
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1968 Beetle torn apart again
1990 Jetta GLI megasquirted, burning E85 (currently in storage)
2004 Jetta turbo GLI
Marion, Iowa |
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NEPAbeetle
Samba Member
Joined: August 02, 2018
Posts: 23
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| Posted: Fri Sep 20, 2024 3:27 am Post subject: Re: Doorskin replacement issues |
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Sorry for the confusion. I cut the door lengthwise near the top and the existing panel dove downward under the new panel.
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Slow-N-Rusty
Samba Member
Joined: March 09, 2020
Posts: 113
Location: SoCal
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| Posted: Fri Sep 20, 2024 12:44 pm Post subject: Re: Doorskin replacement issues |
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Some simple butt welding clamps should get that aligned while you tack things together.
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NEPAbeetle
Samba Member
Joined: August 02, 2018
Posts: 23
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| Posted: Mon Sep 23, 2024 3:41 pm Post subject: Re: Doorskin replacement issues |
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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.
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bomberbob
Samba Member
Joined: May 17, 2015
Posts: 728
Location: Iowa
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| Posted: Mon Sep 23, 2024 7:05 pm Post subject: Re: Doorskin replacement issues |
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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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1968 Beetle torn apart again
1990 Jetta GLI megasquirted, burning E85 (currently in storage)
2004 Jetta turbo GLI
Marion, Iowa |
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