So I pulled off my passenger door and decided to fix some rust on it. Actually, I needed to trim some metal around the upper hinge so I can get it adjusted to where I can work on door gaps some more...but since I had the door off...
I evaluated what needed to be done:
Yep, need to make a patch. So I did.
Checking the fit, it fits pretty good:
I ground the edge and peeled away some rotted metal:
And cut out the bad:
And here's where I ended up tonight. Some more fine tuning, then some POR inside the door, and I can weld it back up. Not too bad of a job, so far I'm about 2 hours into this door:
