60-66 Straighten door curling
 

So the doors on our trucks have a curl or a roll by design at the front fenders. Im trying to get that nice smooth straight line look without the dip at the fender/door line that most of our trucks have. How is everyone able to get that edge leveled up to the fender? I've tried hammer and dolling that lip and its helped and bit but its really more that just the lip. The roll starts a few itches back. My thinking is even if I could get it to come all the way level...between the crown of the door and the roll of the curl ill end up with too much metal and a major oil canning problems. I tried on a spare rusted door to do a little cutting, hammering, splicing and that worked out ok but Im sure there is some better metal magic that I'm missing here. Any ideas? Ive attached a picture of the service manual with what the factory plan was. Looks like an easy fix in the manual. I couldn't get a good picture of the actually door Im working on. Thanks in advance.

Attachment 1757727

Re: 60-66 Straighten door curling
 

You could try shrinking the metal right above where the F is in "2.00 REF" instead of cutting and welding. That being said, the easiest way might be to get it close with a hammer and dolly, TIG weld up the edge, and fill over the whole area (gap and all) then block it, treating it all as one surface and cut the gap open afterwards.

Re: 60-66 Straighten door curling
 

I thought about that but without welding the two pieces together. I was afriad of having too thick of filler on the edge even with it being back up with metal. Itll be pushing 1/8 inch. More worried about what it may look like from the edge after painting. It would be obvious it was filled.
Their was a gentleman on here showing off his blue trucks body lines that was straight as an arrow. I thought it was posted within the last few weeks in the paint and body section but now i cant find it. I would like to know what he did.

Re: 60-66 Straighten door curling
 

1/8 inch buildup is well within the allowable amount for any quality filler. That being said, having the edge built up so you only fill it about 1/32" would be how I'd do it. Google Tyler Krause Inc. He does this stuff all the time and may have some tips on his website.