Surgery

This part of the rust-damaged lower front corner of the driver door was cut out and repaired using a piece from the donor door shell.

The part of the shell where this was removed was similar enough to the damaged area that only a very little reshaping the patch was necessary.

After grinding and offering this piece up to the door a few times to get it right, it was clamped into place to allow it to be stitch-welded in.

The donor door had some rusty areas, but this portion was spotless so this patch was in really good condition so this once really rusty area is in terrific shape.

Welding 18-gauge steel still isn't easy. It burns through easily, especially when there is some pitting from rust, but in the end this turned out well.

After a bit of grinding, it turned out really nicely. This will be put in the media blast cabinet and cleaned up before what will probably turn out to be endless rounds of body filler and sanding.