Step 3:
With your ‘special’ screwdriver, start at the top of the door (at either end) by sliding the blade between the door skin & the frame.
Push down on the handle so as to move the door skin lip up at a 45deg angle.
Slowly & gently continue around the whole of the door.
Continue back the way you came on the lip levering it up at a 90deg angle until the door is free.
Doing it this way, lesions the risk of stretching the skin ‘lip’.
You should now be able to remove the skin from the fame.
Note:
With the door split in halves, you now have the opportunity to carry out repairs on the door frame and/or door skin.
Step 4:
When you have completed the repairs to the fame and/or skin , paint the insides of the two parts with a rust proofing paint or similar.
Next, clamp the two halves together GENTLY with some suitable clamps, into the correct position.
Place a small tack weld at the top ends to hold the skin to the frame – Do not weld it fully yet.
Take a block of wood (to use as a dolly) & gently start working the bottom skin lip over the frame to a 45deg angle. Then start on the side lips.
TAKE YOUR TIME!!!
You also want to make sure you maintain the radius at the bottom rear of the door when your peening the lip over.
Once you have the lips all bent at 45deg angle, you can now completely fold the lips down hard onto the frame.
Take your time here as you don’t want to stretch the lip too much.
Once the lip is down hard, remove the clamps & then weld 20mm down the top of the door at the top (as pictured).
Finally, give the seam & welds a quick wire brush & coat of rust proof paint.
DONE!
You now have the complete door ready to be repainted & assembled!
While it’s a fairly straight forward job, it could be a tad tricky for a novice – so be forewarned!
Question & comments welcome
