Rust repairs to window opening on sliding door

[windy]

Its time to attempt a long overdue repair to the rust along the top of the window opening on my vans sliding door.

Its a converted panel van so the opening is a fairly simple cut, but the repair will need a slight step, so can anyone point me in the right direction as to how to tackle this please?



The bottom of the door is in really good condition, which is a bonus.

[a1winchester]

refer to the wiki if you haven't already done so.

https://club8090.co.uk/wiki/Ar ... dow_frames

Let us know how you get on. (With pics)

[windy]

Thanks for the link, very informative.
Its recreating the swage line I'm struggling with advice for really though.
Maybe it would be easier to buy a repair panel with this already incorporated?

[boatbuilder]

Do you have a joggler? You can adjust the joggler by grinding a bigger or smaller "step" on the jaws to create the size of swage that you want.

[windy]

Thats a good idea. I don't have one at the moment but could probably buy a cheap one & do as you say with the jaws.

[boatbuilder]

I used that technique when I rebuilt the window surround under the left rear window, just above where the cover for the sliding door mechanism sits.
Worked pretty well, well enough to be able to get it perfect with a thin skim of filler.