Door bottom seam required ?

[axisg]

Question for you panel beaters. Doors ( and cab corners ) on my work truck are rotted ( because fjord ). I picked up a less rotted set but they required replacement of the inner door bottom. The outside of the door is fine, but the inner on both were flaky and soft 6" in from either end and an inch or so up from the bottom. I tried to pry the seam open but it was rusty and soft too so I ran the grinder down the door bottom, separated the layers and cut out all the rot. I welded in the patch on the top and sides. When I got to the lower door seam I patched it back together in layers with panel bond on the door, then the patch panel, more panel bond then a strip of steel over top of that making sure to overlap the seams. The repair is strong but now I no longer have that folded over seam on the bottom. Just the 3 layers of steel are on the bottom of the door. I covered it with a skim coat of short strand kitty hair then skim coat of evercoat to smooth it out. After paint I was planning to spray the inner door with a load of fluid film but now I worry without the folded over seam it will possibly break down the panel bond ??

Am I overthinking this ?

 

[melloelky]

yes you are over thinking it,the panel bond is a catalyzed/two part product,it's not gonna soften from the rust proofing spray

 

[Doug Chahoy]

I agree. The only thing I'd have done different would be using metal to metal body filler instead of kitty hair.

 

[axisg]

So I dont have to worry about the fluid film seeping down thru the panel bond and de-laminating then popping the door seam open because I no longer have the fold over to hold it together ? Really If it does it will get a handful of sheet metal screws to hold it back together anyways but really do not want to come to that LOL

 

[joesregalproject]

No, you'll be fine, the panel bonding adhesives (at least all the ones I've used) are catalyzed 2k products. That panel bonding adhesive is tough stuff. At my old job we used to glue on entire roof skins, door skins, and quarter panels with it. We used it for a lot of patchwork too. Also the skimcoat with kitty hair and then evercoat is perfect. We used a product that was a fiberglass filler that was slightly finer than kitty hair, the name is slipping my mind, but it served the same purpose, just to blend and seal the patch panel.

Also I've used tons of fluid film on my truck and it's a great product. Smells kinda gross but it will slow the rust. I I'm sure there are a couple spots on my truck where there is fluid film covering panel bonding adhesive inside the panels somewhere, and it's holding up fine. Fluid film is a pretty mild product in itself, with little to no solvent properties.


So yeah, you're all good!

 

[Doug Chahoy]

Dura-glass was the original finer fiberglass filler. Now every company that makes fillers has a version of it.

 

[axisg]

thx guys, I will carry on the same process on door #2. Maybe even take some pics as it is always an after thought that I should take pictures to chart my progress with this heap of a ford I call a work truck