After the door was dipped I was left with a bunch of pin holes on the inner part of the cab door bottom all along its lower edge.
Also the folded seam of the outer skin was holding the treated rust under it, After bending the lip up it revealed all the corrosion scar along the inner skin.
I decided to cut away the bottom of the door skin and use the cheap repair patch I had rather than make my own repair as I did on the other door.
Using a copper strip (folded from a piece of pipe) on the out side edge I tacked up the pin holes while decent access was available to the inside of the door skin.
The bend block I used to make the other door repair patch came in handy to get the new piece bent correctly, I should have double checked this against the wheel arch so it was bent in the correct position.
The damage along the lip was easily repaired with a bent strip, I made the strips upper lip wider than the original damage so that I was welding and grinding on the flat part and not in the inner radius of the door skin
Once I had the curve correct, I had to trim the repair section at the ends around the curve as it did not fit the doors profile correctly
The experience of doing repairs on the van I found the best result for a clean but joint once ground down are achieved on the external radius of a panel.
With the lower repair finished I think I should have made my own repair piece in one piece rather than cut and patch the cheap one.
I found myself chasing the small pin holes in the door with the welder. They looked like tiny holes on the outside but the corrosion on the inside had really thinned the metal.
