[timothale]

We are at the Farm near Yellowstone for the summer, I Don't know if the tool is still in the body tool box, It was slow to use, but worked where there was limited space. The Big shop is 500 miles south, and I should have some time this comming winter to start on the Car projects. Last winter we rebuilt the south 100 year old farmhouse. New Roof, windows, more insulation Cabinets, tile and hardwood floors wiring plumbing.

[tech69]

Originally Posted by MARTINSR

Yep that is what I am saying, cut that rusted area out with a cut off disc. Run the cut straight down thru the folded lip of the skin but not the outside. Lift the fold a little so you can pull the cut piece out, and to clean the inside of the area for repair. That lip may even need to be completely cut out, cut it out by running a cut along the edge just on the inside of the fold.

Fab the new inner piece, weld it in then cut a small strip of metal to replace the piece of the folded lip of the skin.

Brian

yeah, that's good advice, Brian.

Here's a pic of that repair. The piece replaced on the inner structure was just a small piece. I got lucky by being able to keep the bottom edge but it looks like this fella will at least have a small area where he'll have to weld it on the very bottom of the flange, but doesn't look so bad. Using a file to get your edge straight and a finer one to clean it up works very good for that sort of stuff.

[tech69]

oops, here's the pic

[John68040]

That does seem like a much easier idea. If I do it right, I shouldn't have to do it again for a long time so it wouldn't matter if the welds on the lip penetrated through to the frame. Chances are they would.

[MARTINSR]

That is exactly what I was talking about Henry, you were ready with a photo.

Brian

[tech69]

Originally Posted by MARTINSR

That is exactly what I was talking about Henry, you were ready with a photo.

Brian

next time I'm looking for a job I'll ask them if they want the resume in pdf or
j-peg.

[MARTINSR]

I see nothing wrong with a portfolio showing your work. And not the finished car stuff, the nit and gritty stuff is what I am talking about.

Brian

[deadbodyman]

Originally Posted by tech69

try to peel up the bottom and fix it without taking off the skin. I'd try to peel it back just on the bottom around where you'll be fixing it and have a look to see if it will be possible to fix it that way, if not then plan on the bigger repair. Seems like a
2x4 clamped to the top surface would help while peeling the flange up so the skin doesn't distort. You can also just cut away the flange and fabricate a piece that looks like the flange and reweld it back on after the door frame is fixed. I dunno... just shooting around idears.

Absolutly,,only peel back what you have to to fix the rust.For some reason fords rust inside out and by the time the outer skin gets holes the inner structure crumbles in your hands.I'll post some pics later on I'm out of time and have to get to work...

[deadbodyman]

Originally Posted by Old Fool

Never used them so I don't know if they are worth 6 bucks or not.

Harbor Freight Reviews - Door Skin Removal Pliers

I'm sure those will work even better than mine...Hey ,for 6.00 get them...