The rust repairs begin. The bottom of the left door was dented up and rusted pretty badly. To repair the damage, the rust was cut out and a new panel was fabricated. It was almost the entire bottom of the door. The edge of the lower door skin was pried back so that the new bottom panel would fit underneath the skin as it was originally. The new panel was made out of 20 gauge steel.

As you can tell the bottom of the door is in bad shape.

Here is the bottom of the door with the rust cut out. The inside corner brace was also removed and replaced with a new fabricated piece.

The panel was easy to make as it was almost flat with one 90 degree bend. The new panel is fitted in and held in place with Cleco’s.