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Shaving the Door Handles of A 2007 Chevy Colorado - Get It Handled

 
2007 Chevy Colorado Construction Paper Cover
1a. Bob starts out with construction... 
   
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2007 Chevy Colorado Construction Paper Cover
1a. Bob starts out with construction paper taped over the opening and traces the hole to make a pattern.
2007 Chevy Colorado Cut Pattern
1b. He then cuts out the pattern... 
   
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2007 Chevy Colorado Cut Pattern
1b. He then cuts out the pattern and checks it for sizing in the opening before making the filler plate.
2007 Chevy Colorado Steel Sheets
2. Once Bob has the paper... 
   
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2007 Chevy Colorado Steel Sheets
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
2007 Chevy Colorado Filler Plate
3. Next, Bob checks the filler... 
   
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2007 Chevy Colorado Filler Plate
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).
2007 Chevy Colorado Shaving Down Edges
2007 Chevy Colorado Metal Filler Plate
Part Three: Shave The Doors... 
   
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2007 Chevy Colorado Metal Filler Plate
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.
2007 Chevy Colorado Sanding
2007 Chevy Colorado Welding
2. Once I got the filler plate... 
   
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2007 Chevy Colorado Welding
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.
2007 Chevy Colorado Completely Grinded
3. Grind down high spots in... 
   
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2007 Chevy Colorado Completely Grinded
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.

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