Surgery

This patch panel for the lower corner of the passenger door was cut out of the donor door and the pin holes of rust were welded up. There was a bit more rust in the vulnerable corner where all of these doors seem to rust, but it wasn't so bad that this couldn't be repaired well enough to use. It was just very tedious.

Next the patch panel was fitted to the door.

This patch came from a 1977 Corvette which has a slightly different door, so some areas don't exactly match up. The differences will be slight and easy to erase with some elbow grease. All but a bit of this repair will be covered by the door panel and the rest is on a part of the door that is out of sight.

Once it was welded up, the grinding process began.

A flap disc was used to get all of the welds ground down and make the seams disappear.

After three rounds of body filler, it was getting late. This will be continued before the entire door is stripped down and prepped for epoxy primer and then jamb painted.