Hole in door
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Tuned
Joined: Oct 2020
Posts: 269
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Hole in door
Yesterday was attempting to fix a rattle in my drivers door. Took off the door panel, and started trying to shake things to see where the rattle is. Got to the rear window track, where it is bolted to the door at the rear lower, found a piece of metal had broken out around the washer, so there is a hole the size of the washer broken out. Also cracked further out. The metal is too thin for me to weld, Put a bigger washer over the hole for the short run, any ideas on how to repair this? This is a F-450 '05 model, 191000 miles, and hardly any rust. The door seems in excellent condition other than this hole.
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Tuned
Joined: Oct 2020
Posts: 269
Likes: 25
Alternative welding process gave me an idea. Cut a piece of 1/8" thick steel, 2 1/4 x 2 1/4, ground it a bit to fit the recess around hole, cleaned up both the door and the patch, cut the slot for the window track adjustment, then put JB weld on the piece of steel, and bolted the track back with the bolt through the patch. After it dries, should be a permanent patch. No more rattle.
Fleet Mechanic
Joined: Jan 2016
Posts: 1,804
Likes: 113
Alternative welding process gave me an idea. Cut a piece of 1/8" thick steel, 2 1/4 x 2 1/4, ground it a bit to fit the recess around hole, cleaned up both the door and the patch, cut the slot for the window track adjustment, then put JB weld on the piece of steel, and bolted the track back with the bolt through the patch. After it dries, should be a permanent patch. No more rattle.
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