Questions from my build thread

[Jakes-66-K10]

I'm slowly learning that when obstacles come up, the build thread isn't the place to post questions since it's not as read as normal threads. So, here are a few questions from my other posts that I'm stuck on:


I could use some help on how to properly repair the drivers side door skin. It's pretty badly dented, as shown in these first 2 pics.

The last 2 pics show the replacement skin I've taken off another door. It isn't perfect but I'm thinking of just using say the middle part to replace the left half of the damaged doors. I'm a little worried there could be a noticeable seam down the middle though, if I decided to do it this way.

What do you suggest?

[Jakes-66-K10]

Ooh, and last question of the night is how to prep this area for the outer rocker. I have a compressor but no paint gun. I can get one if it is best to spray my own epoxy primer down on this first.

A local auto paint supply store suggested 3M's Rust Fighter. From what I've read it's some form of body wax that protects against corrosion. However I never read about people using this on the inner rocker. How's the best way to prep this so I can button up my passenger side? 

[Captainfab]

On the door skin, I would use the whole skin. Just grind the edges of the old skin, until you can peel it from the structure. Then fold the edges of the new skin around the perimeter, to the structure of the door. Then you will just have one horizontal seam. If you do weld vertically, you will likely have warpage, that will need straightened.

The inner rocker should have some sort of coating to prevent rust once it is enclosed. An epoxy primer would be good, but you will have to remove it where you will be welding the outer rocker on. You can use a weld thru primer in the areas where you will be welding. It is basically zinc galvanizing in a spray can.

[MOTOIMPAIRED]

Check my build thread but I cut the door skin along the inner bodyline. I found this the easiest place to cut and reweld. once you have the skin off it is easy to hammer the metal straight.

[MOTOIMPAIRED]

Here it is back together with the dent hammered out and rust fixed..

[Jakes-66-K10]

CaptainFab,

I do have some weld through primer. Also have some 3M rust fighter which I guess is a cavity wax spray to use on inner panels. Which do you think would hold up better?

Neither of them seem to be as good of a solution as epoxy primer. But I do want to do things right the first time.
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[bk2life]

metal etch primer a coat, then epoxy after it.

[Captainfab]

I bought some of the copper based weld thru primer, but I haven't used it yet. I have used the zinc based weld thru primer, and it seems to hold up fairly good. I do not have any experience with the 3M Rustfighter though, so I don't know on that. But like bk2life said, some etching primer and then epoxy primer would be the best.