Quote:
Originally Posted by 1971Stepside
Driving up to KC to pick up a new skin this weekend. I'll spend too many hours trying to correct this thing. Now to figure out how to pull them apart.
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How deep is the valley? There's nothing wrong with a little bondo, but I understand the frustration of this repair and not wanting to have to use much filler.
Here's how I removed my skin: Take a flap disc and grind the door edges down until you see 3 layers of sheet metal then stop, drill out one spot weld at the bottom of the window frame, and the outside should come off. Then you'll be left with a narrow strip of sheet metal around all 3 edges on the inside - I was able to cut between the spot welds and twist the shard that's left until it broke loose. There were actually a couple places where the spot weld that was done from the inside melted into the outer skin at the factory and I had to drill those spots. Then I had both sides of the doors blasted to get all the rust out and epoxied both sides.