Tim Suddard
Tim Suddard Publisher
2/26/16 8:14 a.m.

Replacing a damaged door skin: It can sound so daunting at first, like some epic struggle rife with jagged metal and flying sparks. But this job is considered simple in the world of bodywork. Why not just replace the entire door? Sometimes beneath that rusty, damaged or poorly repaired outer skin is a perfectly good inner door frame. That was the case with our Mini Cooper S. Now consider the fact that new and used doors for our car trade in the $1000 range, while properly fitting skins sell for around $100 from places like Mini Mania. The choice seems pretty obvious, doesn’t it?

Our expert body man, Tom Prescott of The Body Werks in Holly Hill, Florida, showed us how to properly replace a door skin using modern adhesive. We chose adhesive instead of old-fashioned welding because it’s quicker, doesn’t distort the metal, and has less of a tendency to rust later on.

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Tim Suddard
Tim Suddard Publisher
2/28/16 8:48 a.m.

Sorry, trying to remove a canoe and deleted the wrong post. A reader was asking about soda blasting damaging metal. We work with Blast Masters and they always neutralize anything they blast, so this is not an issue.

NOHOME PowerDork
2/29/16 12:40 p.m.

A word about the adhesive method.

After replacing a doorskin, you need to put the door on the car and make sure that it still fits. Often there will be a slight twist to the doorframe, and the fix is to give the door a good pull on the top or bottom. Once the door sits flush, you toss in a few spotwelds on the folded edge to lock it in.

Would the cure time on the adhesive allow you to do this?

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