Patching door shell corner

[rustover]

I put a patch in the shell of my 72 Camaro's driver door a couple years ago. I ground down the seam on the front so that the skin would sit flush.

I didn't pay much attention to the back side, which is what you will see when the door is open. Yesterday I got the doors back from blasting. Here is a pic of the backside:

Looking at it now, I probably should have put the weld seam in a different place. I ground it down the best I could:

I plan to get the shells in epoxy. I'm not sure if I should use a smear of fiberglass after epoxy, or seam sealer? What would you guys recommend?

 

[Bob Hollinshead]

I'd finish it off after the skin is on and over epoxy, regular filler will work or if you're not fussy a bit of seam sealer applied right would hide most of it.

 

[crashtech]

If you use filler, there should be no holes in the weld. If there are, fix them by welding, and/or dab epoxy in them til they are sealed.

 

[rustover]

Thanks for the info guys. Crash I do have one very very small pinhole after blasting. It was in a trouble area that I kept burning through. Its so small that the only way I see it, is by putting a flashlight behind it. I'm not sure if I will hit it with a welder again yet. I do have to weld up a hole that I put in the door with the edge of a cutoff wheel, and there are some areas that looked good, but after blasting revealed some major pitting. This is where the weather stripping goes and I'm sure it trap moisture there over the years.

 

[crashtech]

Some people think filling tiny pinholes is hackery, but I don't really think it is in a spot like that. It's more than 99% of guys would do, and it will adequately protect that spot from becoming a corrosion "hot spot," especially if you dab both sides and get it filled good.

 

[rustover]

I worked on this area of the door shell a little more. I decided to hit some of the voids with the welder. I figured it would have just blew a hole, but I actually got them welded up. I also took a cone shape bit and did a little more grinding. I believe this will work. After epoxy I will either just skim with fiberglass filler and sand or maybe just a little seam sealer.