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Old 01-07-2020, 06:48 PM   #1
BaroneDog
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Repair or Replace these Doors?

Working my way through this truck and was hoping the community could help me decide which path to follow with the rusty doors:

Option 1: Buy some patch panels, cut out the old, weld in the new. I would probably patch entire area in the red rectangle area below. Might have to do inside as well since I can see (through the test cuts I made) the inside of the inner panels are also rusted. There are several other rusty areas inside the door which makes me wonder if it is worth it (see images below).

Option 2: Buy some reproduction doors thorough LMC or similar.

Both doors have about the same level of rust.

Thanks for your input!
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Old 01-07-2020, 08:00 PM   #2
nsb29
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Re: Repair or Replace these Doors?

Itís hard just looking at a picture but the rust on the inside looks like surface rust if the only cancer is what you cut out you have a nice door fix it!
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Old 01-07-2020, 08:04 PM   #3
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Re: Repair or Replace these Doors?

sure don't look that bad on the inside..
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Old 01-07-2020, 10:30 PM   #4
Dead Parrot
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Re: Repair or Replace these Doors?

Unless the repair pieces are crazy expensive, give repairing the existing doors a try. At least cut one open and get a better look.
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Old 01-08-2020, 11:26 AM   #5
Daubs
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Re: Repair or Replace these Doors?

My doors are much worse...and I'm going to try and repair them with patch panels.

I've heard the reproduction doors can sometimes be hard to fit and/or not best build quality.

I'd try to repair what you have first.
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Old 01-10-2020, 09:33 PM   #6
BaroneDog
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Re: Repair or Replace these Doors?

Thanks guys. Sounds like it is unanimous, so I will take a shot at repair. Two related questions:

1. Would you cut out the entire area outline in red or just try to keep the cutout spots as small as possible, while being sure to eliminate all cancer (which might result in two separate cutouts)

2. Would you try and treat or coat any of the interior surface rust?
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Old 01-10-2020, 11:27 PM   #7
Bigdav160
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Re: Repair or Replace these Doors?

If it were me I would only patch the spots not the entire lower section
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Old 01-11-2020, 11:24 PM   #8
60chevyjim
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Re: Repair or Replace these Doors?

when I do door corners I cut them a little bigger and all the way to the end and bottom , this way you replace all the hidden rust in the corners , and only have 2 weld seams .
if you don't treat the inside after you weld , the burnt areas will rust faster when they get wet.
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Old 01-12-2020, 08:18 AM   #9
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Re: Repair or Replace these Doors?

I wouldn't cut any more than you have to....
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Old 01-12-2020, 07:03 PM   #10
c60clf
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Re: Repair or Replace these Doors?

I would do whole way across but below feature line, this would help prevent warpage above line and filler should end at line.
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