Rounded Door Corners On A 1956 Ford F-100 - Round And Round

9.With the two separate pieces clamped together tightly, the outer edge was welded back together. This is where you can grind or add to get the door gap perfect.

10.With the top section welded up and ground down, it was ready for a thin coat of mud. The gap was right on.

11.Next, the front section was tacked, tapped on with the body hammer, and welded up.

12.Once again, the inner and outer section matched up perfectly.

13.The outer surface was ground down with a grinder, and a die grinder took care of the hard-to-reach inner edge.

14.Almost perfect. The top edge needed a bit more welding before the mud.

15.Marglass was used in these areas because it is much harder than standard filler. Marco used his finger to smear it into any nooks and crannies in the doorframe.

16.In just a few minutes, the Marglass had set up enough to be knocked down.

17.All the areas were quickly smoothed over and readied for a layer of lightweight filler.

18.A thin layer of Evercoat was applied next and within 15 minutes was sanded smooth.

19.The door area still needed some more sanding, but it took relatively little to get it to this point.

20.Here's the other side already primered and awaiting block-sanding. There you have it. A little cutting, a little welding, and a little grinding, but what a nice touch it lends to the finished product.