Bear with me, these pics jump around a little, I'll explain as I go. Starting with the handle already removed....
This is the right side. I almost forgot to get a pic before cutting on my Sharpie line. Already started the cut.
Chopped it out with a 3" cutoff tool using a 1/16" thick disc. Cleaned it up after this, with a carbide burr.
We actually had an old donor door for this truck, so I cut two patches from it to match the curvature of the door at the handle. That made life simpler. Here I have taped one of the patches up behind the hole.
Then I dusted it with black spray paint and pulled the tape. Thats a magnet holding it up, but now my patch is marked off. I then put the patch in a clamp and cut it on the black's edge.
Heres the ready to zap patch, after fussing over it for awhile to get the gap like I want for welding.
OK jump to the other side, I got in a hurry. This is what it looks like after carefully welding.
And there you have it! After carefully and patiently grinding down the weld, I sprayed a light coat of self etching primer to prevent flash rust until the rest of the door is ready to prime. I was told to just fix the hole in the door, other plans are in place for how to open it but I don't know how just yet.
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