So I finally finished the repairs on the PO's fiberglass crazy attempt to fix the cancer in the fenders and rear cab bottoms. Now on to the doors--which have the same issues-i.e. foberglass patches over very moth eaten metal Here's some pics of one door--the other is exactly the same and I'll be attacking that one today
inside door corner after removal of most of the fiberglass:

After removal of the bad stuff--the brace was cleaned as well as I could, coated with phosphoric acid, and then Rust encapsulator (Eastwood)

Here's how it looks after welding in the patch piece--came out better than I anticipated:

Here's the other side (door skin) in the same location witht he area I'm removing marked out

and with the patch panel fitted and ready for welding--those little rare earth magnets work well for holding things in place for initial tacking

and after welding and grinding a bit here's the final result--ready for some epoxy primer, then a skim coat of body filler, primer-surfacer, sealer and finally paint


Thanks for looking
Bill

 

Thanks for sharing! Great work!

 

That looks much better! You also want to make sure there are no pin holes around your weld area or you will be right back where you started in a couple years. Shine a light against the backside of the repair area and you will see them.

Keep the pics coming!