Sliding Door Repairs

[Merrsh1]

Afternoon

I've got the door off, got the panel (which I ordered 3 months ago from AH Schofield) and I think there is a problem.  The image below has one edge of the panel flush with the corresponding edge of the door. To my uneducated eyes its approx 4mm shy of being a good fit:



Am I missing anything or is it just a bad panel?  I will clarify, this is my first time auto welding...

[davidoft1]

Once you cut off the old panel you will gain a couple of mm either end

[Merrsh1]

Once you cut off the old panel you will gain a couple of mm either end

Cheers, having spent another 10 minutes jiggling it I think it’ll be ok.


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[Merrsh1]

Evening

Looking for some advice / hand holding

I’ve cut out the inner old panel and have a dilemma...

My plan is / was to trim the new panel and then butt weld in the new steel - I’m almost at the point of doing it...

However I’m thinking life may be easier just to use the entire new panel. Any advice / thoughts?

I initially didn’t want to use the entire panel as, only part of the door bottom is rotten and I don’t want to mess with the integrity / curve too much...

Any pro tips gladly taken






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[davidoft1]

Trim the new inner to suit what you’ve cut out of your door, the inner structure looks pretty good and it’s thicker/ stronger than the repair panel, leave the outer on if you can to line up the inner, fit the inner, remove the outer then fit the new outer

[Stesaw]

[Merrsh1]

Trim the new inner to suit what you’ve cut out of your door, the inner structure looks pretty good and it’s thicker/ stronger than the repair panel, leave the outer on if you can to line up the inner, fit the inner, remove the outer then fit the new outer

That's what I've done and that was my thinking all along, its good to know I was heading in the right direction, cheers.

I think it needs to be butt welded but getting the 2 to line up will be a bugger.  Would a lap weld be sensible, I appreciate it will be more work...

I've watched that video (and his second one) a couple of times.  Cheers anyway!

[Stesaw]

I wouldn't know unfortunately I'm no welder, I would assume a lap weld would give a bit more strength but you'd need to make sure you have enough good material to do that, plus I assume putting a lap weld on the outer skin means you'd have to work the metal to make it flush. This is a job I need to tackle on my van at somepoint over the coming months. I've always found his videos very helpful. 

[davidoft1]

Trim the new inner to suit what you’ve cut out of your door, the inner structure looks pretty good and it’s thicker/ stronger than the repair panel, leave the outer on if you can to line up the inner, fit the inner, remove the outer then fit the new outer

That's what I've done and that was my thinking all along, its good to know I was heading in the right direction, cheers.

I think it needs to be butt welded but getting the 2 to line up will be a bugger.  Would a lap weld be sensible, I appreciate it will be more work...

I've watched that video (and his second one) a couple of times.  Cheers anyway!

Lap weld on the inner, it’s fine to do it like that , the outer needs joggling and lap welding