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Fixing Major Dents

Step 5Pry and prep

Pry and prep
With the spot welds removed and the folded portions of the skin ground away from the frame, gently pry the skin from the door. If you meet resistance, stop and make sure all the spot welds have been drilled out. Manufacturers also put sealer between the door skin and the side-impact beam. (This is a solid metal piece that runs behind the skin and connects to the doorframe.) You'll have to pry this joint apart. A crow bar works quite nicely.

When you have it apart, you'll want to clean it. Trust us, the inside of the door is dirty. You could use compressed air --but you may even have to pressure wash it. Use your body grinder to take off the small circles of spot-weld material left on the frame. Also grind off or sand away any putty, glue or other materials that will interfere with installing the skin. Then give the doorframe another cleaning.
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Author:Popular Mechanics
The official instructable for Popular Mechanics magazine, reporting on the DIY world since 1902.