Door repairs on my 1930 Ford hotrod

Both doors need extensive repairs. The bottom sections have rusted through the skin and the frames, not to mention the many dents after 70 years.

Left picture shows rust through outer skin, right shows rust on inside.

Picture on left shows the new inner bottom panel installed and on the right, the new corner frame section. Both sections were handformed and Mig welded in place.

All that's left now is to replace the bottom section with a patch panel and panel beat  the upper sections. Then do the other door, of course ! 

May 2nd, 2000 Thinking about it a bit more, I decided to roll up a new skin to replace the old, from the belt line down. A skin could also be made from a suitable donor panel from the wreckers, such as a roof section, with the right curvature. Only the swage would be needed and the edges would need to be bent over then.

CLICK ON PICTURES TO ENLARGE

the door, rusted bottom, the rest is rough too. Decided to make new bottom half skin.

Homemade, rough set of swage rollers (CHANGED TO STEP ROLLERS LATER)

here is one skin, cut oversize at present.

new skin with bottom swage rolled in Note the slight upwards curve, as per original.

MORE INFO:- SEE NEW PAGE ON MAKING DOOR SKINS

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Jan 2004, updated August 12, 2010