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Door panel

Door panel



1. Remove the anti-corrosion compound so that the spot welds will be accessible.

2. Drill out the spot welds. Be careful to drill in the door panel only so that the underlying door structure is not damaged.

3. Cut the door panel away from the door arch as shown. Take care to cut only in the door panel so that the underlying door structure is not damaged.

4. The door panel is folded over the door structure along the front, rear and bottom edges. Grind through the folds so that the door panel comes away from the door structure.


5. Drill out the spot welds securing the remaining sheet metal strips to the inside of the door structure.

6. Detach the door panel from the putty on the collision member.

7. Knock the door panel loose and lift it away.

8. Use a grinder to clean the door structure.

9. Cut the new door panel roughly to size so that it will overlap the joints on the door by three centimetres.


10. Position the new door panel on the door structure and fix it with a couple of welding clamps.

11. Cut through the door panel and the outer sheet metal of the door arch simultaneously to obtain an edge-to-edge fit. Take care not to damage the inner metalwork of the door arch.

12. Remove the door panel and use a grinder to clean the areas on the door structure and door panel that are to be welded.

13. Apply welding primer to the surfaces which are to be spot welded. Use Teroson Zinkspray.

14. Apply putty between the collision member and the door panel. Use Terostat 1K-PUR.

15. Apply adhesive to the inside of the front, rear and lower edges of the door panel. Use Teromix 6700.

16. Fit the door panel to the door structure and fix it with a couple of welding clamps. Tack weld the door panel to the door arch.


17. Fold the front and rear edges of the door panel round the door structure. Start with a plastic mallet and continue with a hammer. Work along the edges several times.


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

19. Weld the joints between door panel and door arch.

20. Grind the welds clean.

21. Spot weld the door panel.


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

23. Apply primer to all surfaces that have been ground clean. Use Standox 1K Füllprimer.

24. Seal joints and metal folds with putty. Use Terostat 1K-PUR.

25. Fit a slab of sound insulating material to the inside of the door panel.

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