Procedure for changing door skins on 1987 Monte Carlo Doors.
As usual all safety cautions apply. Eye, Face, and Ear protection as well as a dust mask or respirator. I did both doors with skins purchased from Mikes Montes.
Tools Needed: Stable work surface, angle grinder with grinding disk and wire wheel attachment, your favorite rust CONVERTOR!!!! I used 85% Phosphoric acid.(Did a great job), self etching primer, undercoating, Hammer and dollyís, drill and drill bits. I had spare doors I was working on inside my garage. I wouldnít try this on the car.
Optional is an air hammer and the attachment to help fold over the skin. Still a lot of work but I left no marks on the outside of the door from a dolly.
This is what I started with. I thought the door was in good shape but when I took it apart there were some previous repairs and internal edge rust.
Step 1. Disconnect the rods going to the door lock and the door handle. Remove door panel and water shield.
Step 2: Grind the entire edge of the door. You will know you went far enough when it starts to separate. You can see the separation in the left side of the pic. See attached pic.
Step 3. Drill out or chisel spot welds holding door skin to the inside of the door. They are located on the top inner section of each side. You have to grind or chisel out the seam sealer. The door skin should come off at this point. Look at the new door skin to get a better idea of what I am referring to. See attached pics.
Step 4. Remove any parts from door skin you want to keep such as the outer window sweep, door handle and lock mechanism. Keep the skin around for reference when you want to double check how the two top edges of the new skin attach to the door.
Step 5: Remove left over strip of metal from inner door edge. This is held on my spot welds. I just peeled this strip back and most of the welds just popped off. Either drill the welds or grind them with a Dremel tool. Whatever works for you to remove that strip of metal.
Step 6: Clean inside and outside of door of door. Use a wire brush to knock off big pieces of rust or junk. Treat rust with rust convertor, naval jelly, wire wheel, etc. I sprayed the entire inner and outer part of the door with 85% Phosphoric acid. See attached pic. Before and after.
Step7: I used baking soda to neutralize any acid that was left over after convertingto the new phosphate coating. I then washed this off with water and sprayed 70% Isopropyl alcohol to speed the drying process. Doing this on a sunny day helped also.
Step 8: Using a hammer and dolly straighten out the door edge. Use a grinder to knock down any pieces of protruding metal left from the spot welds.
Step 9: One corner of the driverís door was really thin from rust. I made a template and replaced that small section of the edge of the door. To me it seemed important to have a strong edge. I welded in the replacement metal. See attached pic.