That was one of my initial thoughts as well (if I'm understanding what you're describing), but then I needed to figure out cuts in the jambs that would be easy to grind the welds flush on later. What I didn't show in the pictures is that the top of the patch panel is even with the bottom of the opening in the door - I'm thinking about just using the top of the patch as the cut line on the inner panel of the door. That way I just have to weld and grind the 6" or so of the door jamb on each side of the opening and not the whole 36" or whatever it is that the entire width of the door is. I need to double-check the patch and make sure it has all the features there and in the right places, but when I was dreaming about this overnight, that was the direction I was leaning......Hard to describe it, but I'd cut the old inner panel straight along the step down line above those four big dimpled holes. Basically, along the line being made by the bottom edge of the new inner panel as you have it laying in the last two pictures, so that lip at the top of the new inner panel would overlap the 1" or so of the old inner panel that's left hanging down from the cut. You would have part of that upward curving emboss on the hinge side overlapping between the two, but who'd notice since the door trim panel would be covering all of that, same with the horizontal overlap seam, anyway?
Ha! I think I'll be fine with however it turns out. This is my first time attempting a door repair, so I can allow myself a little fudge factor because of that. When the truck gets taken apart in the future to do frame stuff, I can always choose to do a whole new door at that time because I'll likely be doing bodywork and paint as well. One thing that does disappoint me is how thin the inner door skin is and the patch as well....it doesn't give me a lot of wiggle room for getting the seam right - sure can't grind much material off.Remember, Nate, it doesn't have to be all be perfect, a good portion of those patch welds will be hidden behind the door panel. Unless you're so Type A Anal-Retentive that just knowing that spot welds lurk behind your door panel will keep you up at night and a year from now you're popping off the door panel and finishing the bead, DAing, priming and painting your farm beater.
Wow!! You're too kind. I feel like I've shown plenty of my screw-ups, but that's ok, I don't mind showing some failures now and then as long as I push through them and end up successful. I'm here to learn and failure unfortunately is one of the best ways to learn. This forum pushes me to try to do things better, so it's really you guys that are to blame.What I have learned so far about you fixin trucks n stuff. If you think it might work, you will make it work at an excellent level. In fact, I’m starting to think you have to show us a mistake somewhere that turned out bad so we know your not just tricking us all the time! Haha. Chef Ramsey, Martha Stewart, and Nate...
Now, about that skid steer. . . .