Part Two: Making The Filler Plates
There are two options when it comes time to fill the holes in the doors: either make your own or go and buy them. If you buy them, make sure you are getting quality fillers. Sixteen-gauge sheetmetal is ideal- any thinner has a tendency to warp easier and have more blow-through when welding. Grant Kustoms made our fillers for us, but if you want to make them yourself follow along as Bob shows us how.
1a. Bob starts out with construction...
1a. Bob starts out with construction paper taped over the opening and traces the hole to make a pattern.
1b. He then cuts out the pattern...
1b. He then cuts out the pattern and checks it for sizing in the opening before making the filler plate.
2. Once Bob has the paper...
2. Once Bob has the paper pattern perfect, he works the curve of the door into the steel sheets. He then transfers the pattern to 16-gauge sheetmetal and trims it to the outline. It is easier to bend the steel sheets to the contour of the door before the fillers are cut out
3. Next, Bob checks the filler...
3. Next, Bob checks the filler plate, making sure that the piece has a minor recess in the fit, and if any adjustments need to be made he uses a grinder to shave down the edges (inset).
Part Three: Shave The Doors...
Part Three: Shave The Doors
1. I placed the metal filler plate into the door to test for fit. Even though the stamping of the doors is consistent, some additional grinding may be required. When I was satisfied with the fit, I cleaned the paint off the work area all the way to the bare metal. It's best to use a DA sander with 36- or 40-grit sandpaper to rough up the surface of the door (inset). This will help the body filler bond better.
2. Once I got the filler plate...
2. Once I got the filler plate into position I used tape to hold it in place, and then I employed a stir stick to press it firmly in place. Working very slowly to avoid heating the panel too much, I continued tack-welding the area all the way around. To help cool the area down, I used compressed air on the panel in between welding.
3. Grind down high spots in...
3. Grind down high spots in your welds so that everything is smooth. Be cautious, as grinding will generate heat-it could be enough heat to warp your door. This is how it should look after you are done grinding.