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Front door panel

Front door panel

To remove


1. The outer door panel is folded over the door framework at the back and the top. Grind away the fold so that the outer door panel comes loose.


2. Drill out the spot welds.


3. Knock the outer door panel loose and lift it away.

4. Remove the remaining metal folds inside the door framework by grinding off the welds.

5. Align the edges of the door structure and grind clean the door structure.


To fit


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


2. Apply adhesive to the front and rear edges of the door framework. Use Teromix 6700.

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

4. Position the new outer door panel, making sure the metal folds are against the door framework. Secure the clamps.


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 metal fold on the rear edge of the door with a hammer. Do not use pliers as they may damage the outside of the door.

7. Apply a few seam welds along the rear edge of the door where the old spot welds were located.


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

9. Wash away surplus welding primer. Welding primer reduces the adhesion of paint, filler and sealant.

10. Apply primer to all bare metal surfaces. Use Standox 1K Fullprimer.

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

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