Yeah i am going to do that. What is this zinc etch treatment your talking about.

 

www.theruststore.com or www.eastwoodco.com
youre looking for a zinc / phosphoric acid treatment. Theres another variety that uses tannic acid to turn rust into primer but its harder to spray inside body panels and it tends to go on thick

 

Finally got a start on it this evening after work, The rust is gone, got the inner welded in. I laid a solid bead down both sides, the metal is thick on the inner panel. here are some pics.
Attachment 20891 It already started rusting again, cheap primer.

Attachment 20892 All the lower door cut off & ready.

Attachment 20893 Ground down the ends where I laid the bead.

Attachment 20894 Solid bead down each side.

 

I got the outer lower panel welded on this morning & coated with Duraglass. I am leaving for a party, tomorrow is another day.
Attachment 20901 Spot welded in place & luckily there was no warping.

Attachment 20902 Used tape to form a straight body line.

Attachment 20903I just peeled the tape off while the duraglass was still wet. It does a nice straight line if you use the tape trick.

 

Looks good. Keep us updated when you get back.

 

Looking good

 

I only got to work on it for about a hour today. It is crazy around this house trying to get ready for a easter party tonight. I'm really impressed with the panels quality, they are lining right up to the body line, but only thing that I don't like is this. The Panels weren't available for a Quad cab & I had to fab up another panel to extend the bottom rear corner out. The panel had the round bottom on the rear of the door & my Quad cab door goes out into a point. The red line in the pic shows how the panel was.
Attachment 20920

 

I have some seam sealer in a quart can that is brushable. My plans are to coat the inner door & seal up the bottom of the door where the inner/outer panels connect together. I will be drilling some holes across the bottom of the door so that water can escape. Anyone ever use this brushable seam sealer? Does it work well? Is this a good idea or not? Thanks guys.

 

Nobody has used this seam sealer?

 

I think it would be fine they put seam sealer on at the factory over the joints in some places

 

I've used seam sealer & it is great, but never tried brushable. I'm just hoping that it isn't like water.

 

The brushable seam sealer is very nice. It isn't runny like water, it is more like smoothing putty consistency. I filled in the seam at the bottom of the door & coated the entire lower half of the door on the inside. Then I sprayed the inside of the door with spray in bedliner. I don't think it will ever rust again.

 

Anymore pictures of updated progress? And sorry i have never used the seam sealer.

 

I got it finished yesterday morning. I haven't worked on it all week till yesterday, but it is done. I didn't take anymore pics, because the wife yelled at me for getting her camera dusty. I'll get another pic for you.

 

LOL. Sounds good.