This week I wish to share with you the process I went through to replace a rusty door on my daughters little Colt. I have not done this on the Petrolheads Falcon since I have always tried to retain the original metal on that beast. When we had rust in the doors I had the repair done as a metal transplant not a door transplant. Meaning I found a repair guy who makes and reshapes zinc annealed steel for replacement door skins or part thereof! The special part about that is that after making the very rust resistant part he does not weld it. Why not? Well welding breaks the protection of the Zinc and reduces the life of the repair. His trick was to use hi tech glues that join the pieces! I have no photos to share since this was before digital cameras made photography so cheap!
So back to the Colt.
As you may recall this car is a long-term family member. So on presenting it to Jess I had already made plans to fix a few minor blemishes. However. as is always the case with rust, the little spot turned out to be a a nasty case of tin cancer right through the door base. A transplant was the only choice.
Ring Ring Why Don’t You Give Me A …..
So on to the yellow pages to find a wrecker who has what I want. After 2-3 calls I have found a possible replacement and so off in the Beast to collect the door! On arrival at the wreckers it seems the door is still attached to the car it comes with! Anyway the fellow takes me out to check it and it is in good order and will do the job well.
I pay the man and head home!
The removal of the old door is very easy and with the right tools it is off in minutes! I remove all the trim and swap it to the other door. Reverse the removal process and you have the new door on and ready for action.
Add a Little Colour and Away We Go
The next step in the repair process is the adding of a little bit of colour.
The first thing you do is remove all the trim and anything that may be damaged by overspray or sanding.
Next I bog up (highly technical term for plastic filler repair) any holes and sand off the whole door – it is essential that no trace of the glossy top coat is left. If you dont mave a nice mat finish then the new paint may peel off!
I usually sand lightly after the primer is on and add a second light coat. This gives a slightly better finish.
Once the colour has been added (two coats) then I add a clear top-coat to really improve the shine and offer extra protection to the weather and wear and tear.
Allow the door to dry properly and then carefully remove the masking tape. (There is a trick to this and slow and steady is the best way – pulling the tape at 90 degrees to the direction of removal.)
Now just stand back and admire your handy work!
All that is left to do now is allow the paint to cure few a week or two and then I can replace all the trim items that I removed at the start. If you do this too soon the paint may come off with the trim item!
Next time I report on the Colt I will share with you how I repaired the tailgate – it also had a little rust and I gave this a renewal as well!
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