Picking up right where the last blog ended, all the rust was removed with a wire brush on the angle grinder, shot with a few coats of rust converter, and then shot with two coats of Eastwood Rust Encapsulator as seen here.
I could not find a reproduction insulator that goes between the door brace and skin, so I fashioned one out of cork that was the same thickness as the original insulator. I straightened the original staples out and then reused them. I then reinforced it by wrapping duct tape strips over all stapled areas, and finally a duct tape strip ran the entire length of the cork to cover it and hopefully prevent some degradation. The verdict's out on how well it will hold up.
The edges of the door skin were then hammered over and welded to the door. I ground the welds down.
I had a problem with getting tons of tiny little dimples across the bottom from the dolly, even though I was trying to be careful with it. I ended up pushing hard on it with my palm and using that as a dolly.
A new piece is fabricated from scrap metal I saved from the trunk lid. I pounded this on a large pipe to give it a round contour that matched the contour of the door.
The piece was then welded in. It wasn't a perfect fit and there were some big gaps on the bottom and right side, so I had to fill that all in with the welder, leaving it less than pretty, but I've seen much worse weld jobs.
But after grinding down the welds it looks almost as good as new. It won't be in a visible spot and will receive a skim coat of fiber glass filler to cover up any pinholes where the welder didn't completely fill in.