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This is the Chevy we are going to pull parts from.
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BROTHERS has all the sheetmetal to fix your rust problem. This full lower door piece is for the truly wasted door
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BROTHERS also offers separate door pieces that can be used on less damaged doors. This piece is the lower edge of the door
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This piece is for replacing the exterior door skin
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It is easy to see the rust damage to the door on the ’56. The outer skin needed to be replaced.
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The lower piece was also gone. With no place to go, any water will pool in the bottom of the door and begin its process of destruction
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To determine the cut line, we placed the outer skin on the door.
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He then clamped it in place. Because he didn’t need the entire width of the new piece, we marked where the excess will be removed
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Using a die grinder, he cut through the new skin and the door. This way, the two pieces will fit together exactly
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He then cut along the bottom of the door
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The next step was to break the tack-welds on the seam. With these broken, the folded metal could be opened up, allowing the two pieces to come apart
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The outer skin was then removed
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The new BROTHERS lower piece was set on the door and clamped into place.
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It was then marked to be cut.
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Again, it is better to cut both pieces at the same time.
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The door was now open and ready for the new pieces to be tacked on.
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Dave surface-prepped the area with a grinder prior to welding.
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The two pieces were set in place
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The Eastwood company makes these trick little clamps; they’re called Intergrips. The Intergrips hold two pieces of sheetmetal together and leave a tiny separation, which allows the welds someplace to go, rather than just on top.
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A few taps with a mallet ensured that the two pieces were well spaced.
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With that, it was just a matter of welding the pieces together, we made sure to use a rotating pattern and wet towels when welding to ensure that he kept excess heat to a minimum.
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The clamps were used on the lower piece as well.
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Again, care was taken when welding.
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A hammer and a dolly were used to fold the outer skin over the edge.
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Another trick tool from Eastwood is this clamp that crimps the fold tightly.
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The lower piece was massaged into place and welded up.
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With the welding completed, the welds were ground smooth.
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All the pieces were sent to be prepped. Once they returned, they were sprayed with primer inside and out to ensure that rust is never a problem again.
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