Remove top door hinge....?

[highperf4x4]

You'd be better off buying a new door.

Even if you could notch it for the nuts on the backside, it would be tough to weld it in.

[jojo]

Originally Posted by highperf4x4

You'd be better off buying a new door.

Even if you could notch it for the nuts on the backside, it would be tough to weld it in.

X2

I just did this fix. It sucked.

I have pics of my repair job on 2 doors that were otherwise good. Check my build thread pages 4 and 5. It's not a write up or anything just some pics.

My original plan was to cut the damaged section off the "new" door. Then use the old door as a donor for a patch panel.

The problem is, you can't just cut that section out and weld something in, its braced internally with all kinds of bends and angles... And all my cutting devices just caused more damage.

So ended up stuffing some sheet metal behind all that stuff and welding it in. It's solid now and would look better if it was'nt my first official repair with a welder.

My opinion is that it can be done but not easily (provided that the damage is similar to what I had and your bolt hole plate is solid).

I also don't think that you'll have enough heat to damage the paint on the outside of the door. Mine never got hotter than my bare hand could touch on the outside. Granted, my doors are not painted so I cant say for sure.