F60L Recent pics

[Phil Waterman]

Hi Tony

Your prep of the metal in the door is what is key to a good job. Clean bare steel is going to weld best. Having done a similar job on my Pat 12 and Pat 13 re-skinning both doors I would echo Grants comment on using a brake to form all the straight sides.

On the HUP door I used heavier than original steel and it was much harder to get sharp bends, on the Pat 12 went with same gauge as original and did all the bends except the curved section with the brake. For the curved edge I used a similar method to what Mike describes.

As to Bobs question about welding I have done it both ways, plug welding as described in the discussion of repairing cracks in hinged area, drilling through two of the three layers seems to work best if the metal is rusted or pitted. While pinch welding works good when all three layers of steel are clean and bare. But as previously discussed in other threads pinch welding is limited in the thickness it can effectively weld.

I've also used as Grant suggest panel adhesives on to re-skin doors on modern cars.

Keep up the great detail work Tony

Cheers Phil