Originally Posted by perryg114
I think removing the inner skins is the thing to do cracks or not. Leaving it on the trailer may not be a bad thing because you have the opening to provide a reference to get the correct contour.
For simplicity, we always removed the interior metal, and closed the door.
Then we made the door fit properly.
Next, we tack welded the crack.
Then we finished the welding after we opened the door.
Of course, double checking to make sure nothing went wrong.
Part of fixing the cracks in a cast frame was to taper the cracks, which allowed a full weld.
You can do somewhat the same thing, but to a lesser extent to the extrusion
When reinstalling the old metal, DO NOT use the same holes, since they have wallowed out. Install new rivets in new holes, which locks the door into a proper angle, Then, and only then, after double checking the fit, install rivets into the old holes, which now serve nothing more than a decent appearance.
Restoring the original interior door strength is most important, and using just the old holes, will not in any sense allow that to happen.