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1961 - 1966 F-100 & Larger F-Series Trucks Discuss the Slick Sixties Ford Truck

Door Crack

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Old Jun 21, 2023 | 03:02 PM
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Door Crack

What is the proper procedure to fix a crack in the door?
Looks like it started around the hole where the inside door glass wiper clip goes in.
Should this be welded or can it be fixed using a mixture of JB Weld?
 
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Old Jun 21, 2023 | 05:00 PM
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It should be welded, mig or tig.
 
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Old Jun 21, 2023 | 08:03 PM
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Metal=metal....so weld. JB is plastic.
 
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Old Jun 22, 2023 | 06:46 AM
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Originally Posted by sonny1965
What is the proper procedure to fix a crack in the door?
Looks like it started around the hole where the inside door glass wiper clip goes in.
Should this be welded or can it be fixed using a mixture of JB Weld?
Do you have any pictures of the crack?
 
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Old Jun 22, 2023 | 10:45 AM
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Thanks for all your help.
 
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Old Jun 22, 2023 | 02:34 PM
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The 80 - 86 trucks do the same.
On them there is a metal bracket welded to the inner & outer door panels and that bracket breaks off one side and the crack starts.
Now this seams to happen more on trucks that have the larger mirrors, not the car sport mirrors.
The weight of the larger mirror hanging off the side, slamming the door closed and road bumps shakes the outer panel and the bracket breaks and then crack follows.

I dont know if your years have this little welded bracket or not?
Dave ----
 
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Old Jun 22, 2023 | 06:12 PM
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Both of my trucks have the cracks hinted to, (need pics to confirm). It seams to be a more brittle area that cracks from years of vibration and pulling on the doors to shut them.
 
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Old Jun 22, 2023 | 06:22 PM
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Are you talking about these cracks?


 
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Old Jun 22, 2023 | 07:49 PM
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Common spot. When welding, I would put a little backing plate in there....
 
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Old Jun 22, 2023 | 08:17 PM
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The reason it cracks there is because of the void in the area below the crack.
The key to stopping the cracking is to fill in that voided area. The door will no longer flex in that area.





 
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Old Jun 22, 2023 | 08:29 PM
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Nice fix
I did see that void and thought no wonder why it cracks there.
How close is the mirror to the crack?
Your door is different than my 81 but thought I would bring it up about the bracket just in case yours had one also.
Dave ----
 
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Old Jun 22, 2023 | 08:46 PM
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Originally Posted by FuzzFace2
Nice fix
I did see that void and thought no wonder why it cracks there.
How close is the mirror to the crack?
Your door is different than my 81 but thought I would bring it up about the bracket just in case yours had one also.
Dave ----
The crack on these 61-66 doors is away from the mirror, closer to the door handle side.
 
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Old Jun 23, 2023 | 06:37 AM
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Originally Posted by instig8r63
The crack on these 61-66 doors is away from the mirror, closer to the door handle side.
The handle is only bolted to the outer skin so I guess it is the pulling & pushing on the door handle and that weak spot then fails over the years.
Dave ----
 
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Old Jun 23, 2023 | 06:46 AM
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Originally Posted by FuzzFace2
The handle is only bolted to the outer skin so I guess it is the pulling & pushing on the door handle and that weak spot then fails over the years.
Dave ----
The crack is on the inside of the door so, yes, I suppose it’s from pulling the door shut.
 
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Old Jun 23, 2023 | 08:12 PM
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OP won’t respond, so we don’t know if we’ve been helpful. 🤷🏻‍♂️
This is why I’m hesitant to waste my time on a reply.
 
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