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Front door, outer door panel

Front door, outer door panel

To remove


1. The outer door panel is folded over the rear and top edges of the door structure. Grind the edges so that the door panel comes away from the structure.


2. Drill out the spot welds.


3. Knock away the outer door panel and lift off the outer door panel.

4. Remove the remaining metal strips from the inside of the door structure by grinding away the welds.

5. Straighten the edges of the door structure and grind it clean.


To fit


1. Apply sealant on the impact members, use Terostat 1k-PUR


2. Apply glue on the door structure's front and rear edges. Use Teromix 6700.

3. Apply weld primer on the lower edge of door structure. Use Teroson Zinc spray.

4. Align the new outer door panel and make sure the plate flanges lie against the door structure. Secure with grips.


5. Spot weld the front edge and underside of the door frame. Tap down and clamp the upper flange on the outer door panel.


6. Knock in the plate flange in the door's rear edge using a hammer. Do not use pliers as this can damage the outside of the door.

7. Stitch weld along the rear edge of the door. Place the welds where the old spot welds were located.


8. Fit the door in place and check its alignment with the body. Adjust as necessary.

9. Wash off surplus welding primer. Welding primer makes for poorer adhesion of paint, filler and sealant.

10. Apply primer on all ground surfaces. Use Standox 1K Primer Filler.

11. Use Terostat 1K-PUR to seal joints and metal folds.

12. Apply anti-corrosion agent to the door after it has been painted.