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240 door pillar needed - no more 200

posted by  streetdreams on  Sat Dec 25 11:45 CST 2010
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last visit: Thu Sep 18 18:27 CST 2014
[RELATED]

I just wanted to thank everyone who tried to help me out. I no longer need to cut out a pillar. A couple weeks ago I pulled the drivers door off and part of the interior and the fuse panel, cut out the rusted section and made a new one out of left over heavy gauge sheet stock my father-in-law had lying around. I doubled it to the back where the fuse panel used to be and welded them together. I made a template out of cardboard first and then patchwork welded them together. It looks like Frankenstien's forehead but I hung on it with all of my 200 lbs of fat and it holds up. I hit it with a coat of fast dry black rustoleum which took 2 days to dry because of the cold weather. So far so good. The only drawback was the curve at the bottom of the door and rocker is now more angular. The door lined up after I adjusted it twice, but I scratched the paint in one spot the first time I closed the door. All in all it took about a day of work, 2 grinder disks, 1 new welder tip, a couple hundred feet of welding wire and a can of paint. Not bad for under 25 bucks.






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