Well, it's make it or break it. Hopefully I'll come out of this with a good door, and a welder, and some other new tools, but I guess if I have to scrap the door I still win. The inner lower door patch piece doesn't quite look like what I have (the lines, not the lack of rust...), so I'm going to try to preserve what little is left down there to keep things looking right.
Here's my progress. Armed with all my new toys I took the plunge I was afraid to take. Unfortunately, I think the easy part is over.
I think this is a pretty typical looking rust belt door. I've seen better and much worse, actually...
Ok, time to tack on the new pice, and we're all done!