Here we have begun the rust repair on a rear door. I know it may look a little strange if you haven’t been inside a 677 rear door before but what you’re looking at is what appears to be the lower section of a front door inside the carcass of the rear door. The rear doors are actually made from existing front doors and metal is added to the bottom to square off the door to fit the rear opening. Kevin has sand blasted & primed the inside of the door after cutting out any questionable metal.

This picture shows the cut out rusted section and the replacement patch panels that have been formed to repair the door.

Here is the rear door all ready to begin adding the patch panels. Work starts on the inside door frame first.

The inside framework pieces are set in position and tacked in place.

A few more skip welds and the back side is done!

Here you can see the back side is now finish welded, sealed, and ready for the outer skin to be welded in.

With the outer skin positioned and tacked in place this door is ready for final welding. Now it is onto a bit of priming & block sanding to get things just right.