10-4-2006 THE DOOR
The door was badly kinked when the base of the door was trapped in-between the crashing Porsche and the guardrail.
The door skin is the same 2024 T-3 Alclad as the rest of the siding. The inner door shell is pure untempered aluminum. It is very soft and was tough to flatten out.
I spend hours and hours straightening the metal. The more I did the worse it looked. I tried polishing and it looked even worse.
I decided to install a patch panel over the distressed metal. I mimicked the radius of the door and riveted it in place. The patch is Alclad and is covered with a layer of pure aluminum. It will polish out the same as the door stamping.
I replaced the door skin because the guard rail had burned through the layer of pure aluminum and stretched the metal. Taking the door apart allowed me to straighten the inner door instead of trying to find a 55 year old replacement.
The replacement door skin was simple to duplicate, as were the side panels. I used the old door skin as a template.
There are some inner stiffeners that needed to be riveted to the door skin before installation on the door back.
The lock bezel opening needed to be closely cut for strength and appearance. Lots of 1/8" holes and smoothing with a carbide burr.
Test fit the door skin and drilled all rivet holes. Then I deburred holes for a tight fit of panels.
Installed new insulation.
Completed riveting door perimeter and cut out window opening. This was done last so that the panel went on without buckling along side the window opening.
Installed. Perfect fit.