Repairing the bottom of the sliding door
This was carried out early in the rebuild and I had not yet bought the digital camera so the quantity and quality of these pictures is not as good as other work.
The door has been stripped of all it's parts, glass, handles, inner trim etc. It has also been rubbed down.
At this point I have marked off and cut the outer skin at a convenient height. I have not cut any of the inner structure yet as it is vital that the height of the door is maintained. SO before you even start going at it with the grinder you need to mark the door up so that you end up with a repaired door that is square and is the same height and width as it was before you started.
It cannot be seen on this picture but I had drawn an imaginary line something like 500mm from the bottom of the door that went right across, I may even have done it on the inside of the door. The idea being that when it comes to welding the new piece on, I make sure that it's bottom edge is 500mm from the line I had drawn meaning that the repaired door is the same height as the original.
The corrosion does not look too bad in this picture but believe me it was shot away and some bright spark thought that it could be repaired/hidden by putting 4 tons of filler in it!!
Again, not a totally brilliant picture but here I've cut the inside structure away and you can see the old piece compared to the nice new black repair section. It is vital that all measurements and markings are accurate.
Here I have tacked the inner repair into place by placing the outer repair in position against the measurements and markings I had previously made, laying the inner repair into position and tacking it in. I did the inner first so that I could get a good seam weld both inside and outside as it would be difficult to do if the outer repair section was welded on first.
Now the outer repair section is positioned, you can actually see one of the lines marked on the door here. I did remove the repair and grind up the edge of the weld area before I actually got the mig near it.
Here you can see the outer repair seam welded into place. This needs extreme care due to the large flat area that you are welding it is vital that you do it in very small sections so that the door or repair section does not warp.
Door turned round, anti-corrosion paint and seam sealer applied.
Spray the outside to stop any corrosion
And here it is all rebuilt and it does look rather smart.