240D door rust repair
IMG_00013.JPG
Rusty door corner
IMG_00014.JPG
Inside view of rust
IMG_00015.JPG
IMG_00015.JPG 2009-08-04
IMG_00016.JPG
Cut section out with air cut off tool
IMG_00017.JPG
Notice rust in inner door
IMG_00018.JPG
Perforated metal in inner door cut out
IMG_00019.JPG
IMG_00019.JPG 2009-08-04
IMG_00020.JPG
Beginnings of inner door patch panel fabrication. Bend made with a sheet metal brake.
IMG_00021.JPG
Shrinking machine used to shape bent metal.
IMG_00022.JPG
IMG_00022.JPG 2009-08-04
IMG_00023.JPG
Another bend made. Piece slowly taking shape.
IMG_00024.JPG
IMG_00024.JPG 2009-08-04
IMG_00025.JPG
Underside of patch panel looking more and more like original piece.
IMG_00026.JPG
IMG_00026.JPG 2009-08-04
IMG_00030.JPG
IMG_00030.JPG 2009-08-04
IMG_00031.JPG
This is a tuck. It will be hammered down and the end result will be shrunken metal. When the metal shrinks then the be
IMG_00032.JPG
IMG_00032.JPG 2009-08-04
IMG_00033.JPG
IMG_00033.JPG 2009-08-04
IMG_00034.JPG
Some more shaping of the metal by pounding (stretching) over a shotbag.
IMG_00035.JPG
Planishing or smoothing out the metal by hammering over a post dolly.
IMG_00036.JPG
IMG_00036.JPG 2009-08-04
IMG_00037.JPG
IMG_00037.JPG 2009-08-04
IMG_00038.JPG
IMG_00038.JPG 2009-08-04
IMG_00039.JPG
IMG_00039.JPG 2009-08-04
IMG_00040.JPG
IMG_00040.JPG 2009-08-04
IMG_00041.JPG
IMG_00041.JPG 2009-08-04
IMG_00042.JPG
Finished patch welded in place.
IMG_00045.JPG
Weld bead ground down flush with surrounding metal.
IMG_00044.JPG
Inner view of patch welded in place.
IMG_00046.JPG
Weld bead ground down from the inside. This is not necessary unless you have to work the weld with hammer and dolly. I
IMG_00043.JPG
IMG_00043.JPG 2009-08-08
IMG_00049.JPG
Beginnings of outer patch panel.
IMG_00050.JPG
IMG_00050.JPG 2009-08-09
IMG_00048.JPG
Access hole drilled in inner patch panel.
IMG_00047.JPG
IMG_00047.JPG 2009-08-09
IMG_00051.JPG
More work on the shrinker to form curve.
IMG_00052.JPG
IMG_00052.JPG 2009-08-10
IMG_00053.JPG
IMG_00053.JPG 2009-08-10
IMG_00054.JPG
IMG_00054.JPG 2009-08-10
IMG_00058.JPG
Outer patch tack welded in place. Tacks are placed every 3/4 inch. You have to jump around the panel when you do this
IMG_00059.JPG
IMG_00059.JPG 2009-08-20
IMG_00060.JPG
IMG_00060.JPG 2009-08-20
IMG_00061.JPG
Tack welds ground down on both sides of panel to allow hammer and dolly work over welded areas. This is necessary to mo
IMG_00062.JPG
You weld between tack welds and jump around to avoid too much warpage. Also if you continue to weld without jumping aro
IMG_00063.JPG
All welded up and ground down.
IMG_00064.JPG
IMG_00064.JPG 2009-08-20
IMG_00067.JPG
IMG_00067.JPG 2009-08-20
IMG_00066.JPG
Edge folded over
IMG_00069.JPG
IMG_00069.JPG 2009-08-20
IMG_00068.JPG
Despite my best efforts, some heat distortion still exists. Stretching the HAZ is difficult to do in tight confined spa
IMG_00070.JPG
IMG_00070.JPG 2009-08-20
IMG_00071.JPG
Studs cut and ground flush with surrounding metal.
IMG_00072.JPG
IMG_00072.JPG 2009-08-20
IMG_00073.JPG
Contour of original caulk bead was duplicated with my finger, some masking tape and a putty knife.
IMG_00074.JPG
Primed and ready to go to body shop for painting.
Garage pics
IMG_00008.JPG
IMG_00008.JPG 2009-08-03
IMG_00009.JPG
IMG_00009.JPG 2009-08-03
IMG_00007.JPG
IMG_00007.JPG 2009-08-03
IMG_00006.JPG
IMG_00006.JPG 2009-08-03
IMG_00003.JPG
IMG_00003.JPG 2009-08-03
IMG_00001.JPG
IMG_00001.JPG 2009-08-03
IMG_00002.JPG
IMG_00002.JPG 2009-08-03
IMG_00011.JPG
IMG_00011.JPG 2009-08-03
IMG_00012.JPG
IMG_00012.JPG 2009-08-03
IMG_00010.JPG
IMG_00010.JPG 2009-08-03
IMG_00005.JPG
IMG_00005.JPG 2009-08-03
IMG_00004.JPG
IMG_00004.JPG 2009-08-03