Well, I finally got tired of the wore out compressor spewing oil everywhere. We went out this AM and (after going to the farmer's market, pool supply store, and floor covering store), we brought home a new compressor. Got it all hooked up and operational. On one hand it is distressing that is all I got done today. On the other, this should make future work easier and quicker.
Filled the voids at the back lower edge of the door. Ground the bottom of the door for the rear 15 -16 inches back and then welded. Marked the gap and ground back to it. Also trimmed the top rear portion that was still a little too tight. Marked the front edge for grinding once removed from car. Door will come off once the front top part is welded and ground.
Well, I thought this door would go quicker than the other. Oh well.
Started off the evening having to nurse the compressor. Next work session is going to be either replacing the pump or replacing the whole unit. It's 19 years old so it doesn't owe me a dime.
Finished welding up the bottom. Did all the grinding. The rear edge is lacking enough weld so I have to fill some spots. The bottom looks great from the outside. But, I apparently did not grind it back far enough before welding. Grinding it to fit opened up the bottom of the seam on and off for the first 14 inches or so from the back of the door forward. So, more welding and grinding on the bottom. But that will have to wait until the compressor is back up.
Ten hours might have been a little optimistic. I only have abut 4-1/2 left.
Measured and marked off the bottom. It needed ground and welded all the way across. After tacking, small sections were welded and cooled with a blow gun. The heat was controlled with the compressed air and jumping around. Slow and tedious. The dirt and rust in the seam slow things down even more. The welding on the bottom is about 75% done. Got dark and had to go in for dinner.