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Hello,

The upper frame of my passenger door is badly rusted through (see picture). What do I do about it? Also, I reckon there is an area at the lower front of the skin the has been filled. Will I have to find another door with a decent frame to cut out and weld into mine? I may be able to delicately repair it. I would assume there are no repair panels.

Also, as this is my daily driver, what are my chances of finding somebody in the south with a spare door they'd lend us while I took mine out to weld. Cheers,

That doesn't look good. Not what you want to hear I imagine.
There's a good chance the channel behind that section is rotted out as well.
The channels are available from M Machine.
I don't think those sections of door are available, well I haven't seen any for sale.
The only option then would be to get a scrap door and chop that section out or fabricate your own.
I went to look at a pair of early doors last week, but to be honest the amount of work that needed doing to them made them seem rather expensive and someone had already botch repaired them before. So I walked away.

that door is scrap, the part in your photo isnt available new (bar as part of a complete door) and if the rust is bubbleing through there its fair to assume that the trough part is rotten as well (which is where the water will have got in from).

to repair the trough you have to remove the skin and then undrill it from the frame, once all thats gone there wont be much left.

i would say that by the time you have 'made good' the part in your picture (either by chopping up another door, or making a feindishly awkward repair panel) you would have been better off starting with a better example as i would guess that the door frame will be rotten at the bottom as well.

Yep, as I thought. I will have to get my eye out for a new door. Might be best to find both driver and passenger. Drivers door seems to be ok but the skin seems to bulge out by around 1/2". I thought it might have been filled but the inside of the skin also bulges out. I dont know how it got this way. Cheers,

Daniel,

I have a couple of doors available - they have already been dipped and stripped then given a light coat of primer. They aren't perfect but reasonably solid - no repairs made yet but they are a lot better than yours I think so you could more easily repair them - I can send you some photos if you like via PM. I'd only be looking for a little bit of cash and I'm based in Gloucestershire so maybe not too far away?

Cheers,

Chris

Sounds very interesting. Send us some photos. dhlackey(a)gmail.com. Cool,

Will do - out at RaceRetro tomorrow so might be Sun but will email you with pics etc.

Cheers!

Chris