2nd Gen Non-Engine/Transmission Lower doors rotted, Patch panels.

[Cummins724]

I wanted to fix my lower doors, but didn't want to have to paint my truck. I am gonna get the lower part on my truck which is silver sprayed with line-x, but needed to get some good metal welded in before coating it. I called LMC truck & ordered their lower door inner/outer panels to patch it up. Here are a few photos of my progress from yesterday, I am doing it in my spare time.

View attachment 68458 The entire inner/outer was rusted apart.



View attachment 68459 I cut the entire inner/outer off & got it ready for the panels.



View attachment 68460 After laying a bead down each end [metal is thick enough in that area. I ground it down smooth.



View attachment 68461 Shows the inner panel welded in before grinding.



View attachment 68462 Spot welded the outer panel in place with no warping.

 

[Cummins724]

Here are a few more.

View attachment 68463 I used tape as a guide to assure a straight body line.



View attachment 68464 Peeled the tape when the duraglass was still wet, you can see that the line is nice & straight.

 

[DSeamans]

be sure and reseal inside the door where you seamed or it will rust out in no time. Try to get in the lap of the seam. Metal on metal with no sealant is bad news. Moisture gets in between the layers and its all over. They make an epoxy adhesive for door panels that works very well. I've used it a few times with great luck. If you try it, get the slowest cure time. Trying to roll the edge seam when the epoxy has started setting up is no fun either. Post more pics when ya get it done.



Dave

 

[DCreed]

dont forget to add drains or it will fill with water.

 

[DSeamans]

I forgot to ask about the quality of LMC's tin. I'm getting ready to completely redo my 01. LMC is one of a few places that have QC doors and parts. Did the stuff feel as heavy as stock or was it pretty thin like a lot of taiwan tin? I saw their doors are $400 vs mopars $700.

 

[Cummins724]

be sure and reseal inside the door where you seamed or it will rust out in no time. Try to get in the lap of the seam. Metal on metal with no sealant is bad news. Moisture gets in between the layers and its all over. They make an epoxy adhesive for door panels that works very well. I've used it a few times with great luck. If you try it, get the slowest cure time. Trying to roll the edge seam when the epoxy has started setting up is no fun either. Post more pics when ya get it done.



Dave

I bought a quart of brushable seam sealer & plan to coat the entire inside of the door with it. I also put the Door skin adhesive on around the edges before I wrapped the skins.

dont forget to add drains or it will fill with water.

I am going to drill holes all the way across the bottom of the door.

I forgot to ask about the quality of LMC's tin. I'm getting ready to completely redo my 01. LMC is one of a few places that have QC doors and parts. Did the stuff feel as heavy as stock or was it pretty thin like a lot of taiwan tin? I saw their doors are $400 vs mopars $700.

I think the panels were the best quality aftermarket that I've seen. I've done many patch jobs over the years & I know what you mean. Most panels are to thin & come wavy from the factory. These seem thick as, if not thicker than stock. Only thing that I don't like is that the outer door skin isn't available for a quad cab, had to buy a standard door skin which came with the round bottom. I had to make a panel to extend the bottom rear of the door to a point.

 

[DSeamans]

Dang it! I just zoomed in on the page and it says club cab not Quad cab. I had to make a set for the last one I did also. Anyone know where to get QC doors and/or patch panels?

 

[Cummins724]

Dang it! I just zoomed in on the page and it says club cab not Quad cab. I had to make a set for the last one I did also. Anyone know where to get QC doors and/or patch panels?

I checked everywhere for the quad patch panels, not available. I called the local parts yard & found a few doors in perfect condition for $400-$500. I just didn't want to paint my truck so I went with the patch panels.

 

[Cummins724]

I bought this brushable seam sealer & was wondering if any of you guys have ever used it?

 

[DSeamans]

Epoxy adhesive

They make an epoxy adhesive for door panels that works very well. I've used it a few times with great luck.



Well, I now retract this statement. I put rear wheel arches in my buddies 98 last fall and they just cracked - both sides. You can't imagine how POed I am. I spent 2 1/2 months redoing the whole truck and now this. It did look better than new. Now I either have to find a new box or grind everything off and weld them on. Have a better day than I am!#@$%!

 

[Cummins724]

They make an epoxy adhesive for door panels that works very well. I've used it a few times with great luck.



Well, I now retract this statement. I put rear wheel arches in my buddies 98 last fall and they just cracked - both sides. You can't imagine how POed I am. I spent 2 1/2 months redoing the whole truck and now this. It did look better than new. Now I either have to find a new box or grind everything off and weld them on. Have a better day than I am!#@$%!

That sucks, sorry to here that. I'm glad that I decided to weld my panels in. I'm getting ready to get the Line-x sprayed on this week. Here are a few pics of the door. I sprayed it with silver paint that I had laying around & it doesn't match, but its not too bad.

View attachment 68638 I managed to keep the door gap nice & even.



View attachment 68639 I just ground the welds down on the inside & sprayed the bedliner spray on for protection.



View attachment 68640