I just bought mint rust free doors. I put them on, got the doors to align properly, then set about adjusting the windows. I just got the windo perfect when I notice that the number one rivet holding the motor on (the one furthest up ) had cracked the metal around it when I was adjusting it. I have nev er adjusted the window before, and I didnt read the artcile beforehand (want aware of it ) but I just read it and I think I was doing everything right. The insied panel of the door, where the motor is rivetted, also seems to flex inward excessively when the window reaches the top. What would cause this? Is this door a lost cause, or can I fix the damage? Please advise
-Brendan

 

most thirdgen doors that ive seen have had this crack. it just seems like a weak area under alot of stress from the motor. ive never heard of anyone having a problem with the crack being there as long as it isnt huge.
matt

 

I think I am going to weld the cracks, smooth, weld a washer over them, then weld in some thick bar stock to keep the area from flexing again. Think that would work?

edit... If i don't do something about it, it will get huge. there is no reason the area should flex like that either, with proper reinforcement. I just verified with my other door that the flexing isnt anything out of the ordinary.... however, metal fatigue is cumulative, and i want to stop this before it becomes a problem. I'll probably do the same for the other door i'm installing too

 

 

Maybe I should rephrase that.... has anybody else reinforced that section? Is it a good idea? Or, should I just repair the damage and call it good?

 

I just picked my car up from having this done only a few minutes ago!

The cracks were welded and smoothed and a plate was welded on top of that and re-rivited.

So my answer is "It cant hurt to fix and reinforce it".

 

I just did this exact same thing to my door 2 weeks ago. On my door the stress of the rivet actually blew a hole right through the sheetmetal in the door.

I definately recommend doing the same thing as Scottlb9 did. You wont have to worry about it happening again!