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For the original story, go to popularmechanics.com.
This project is not for your everyday door dinger from bumping another car or object in the street --these dents require repairs that involve more than a hammer and body-filler. We're talking about a dent --one that is big enough to stretch the metal well beyond its original shape. For this sort of door damage, you have two options --find another door at a wrecking yard, or reskin the door you already have. Recent developments in structural adhesives make the second choice a good alternative, with no welding required.
Most sheetmetal doors are made in three pieces. There's the frame (which the inner door panel and armrest attach to), the window channel (which is welded to the doorframe) and the skin (which attaches to the doorframe and the outside of the window channel).
This project is not for your everyday door dinger from bumping another car or object in the street --these dents require repairs that involve more than a hammer and body-filler. We're talking about a dent --one that is big enough to stretch the metal well beyond its original shape. For this sort of door damage, you have two options --find another door at a wrecking yard, or reskin the door you already have. Recent developments in structural adhesives make the second choice a good alternative, with no welding required.
Most sheetmetal doors are made in three pieces. There's the frame (which the inner door panel and armrest attach to), the window channel (which is welded to the doorframe) and the skin (which attaches to the doorframe and the outside of the window channel).
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Signing UpStep 1Taking off the door
To replace a skin, you must first remove the door of the car. Procedures vary depending on the vehicle, but the place to start is by taking out the inner door panel and the window glass. Next, remove the insert inside the window channel, and any trim or molding around the window frame and on the door skin. You also have to remove the mirror, and the door lock and handle. Use a body shop repair manual specific to your vehicle if you have doubts about how to remove these items without doing damage. Unplug any wiring that runs from the body through to the doorframe. Next, scribe around the door hinges on the car body to mark their location, then have an assistant hold the door while you unscrew the hinge bolts. Keep in mind that even with much of the inner workings of the door removed, it is still heavy, so get some able-bodied help.
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I have rust on the edges of my car's doors. I'm considering grinding off the folded portion and welding on a new strip of sheet metal, which I will fold into place. The result will be ugly, but the door will still shut properly.