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Door lock hole repair

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Old Jul 30, 2025 | 02:11 PM
  #1  
aldrichg9's Avatar
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From: Terre Haute, IN
Car: 91 RS 5 speed
Engine: 305
Door lock hole repair

Has anyone fixed damage like this?
im assuming someone tried to break into this car long ago.

just got a rough quote from a pdr guy for $750-$1100.
I won’t be able to proceed down that route so I’ll try it myself.



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Old Jul 30, 2025 | 04:25 PM
  #2  
69-er's Avatar
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From: Alamogordo, NM, USA
Re: Door lock hole repair

I think it would be very difficult to get behind there with a dolly in an attempt to pick/hammer it to shape. My first thought is to find a donor door and cut out the lock hole, about 3" x 3", and weld it in. The costly estimate is from the repair, keeping it flat, filling and blocking it smooth and paint.

It won't be difficult to do but somewhat time consuming.
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Old Jul 30, 2025 | 06:35 PM
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84 1LE's Avatar
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From: Oyth
Car: 89RS vert
Engine: Erod
Transmission: 4L65e
Axle/Gears: BW, 3.27
Re: Door lock hole repair

I think there's plenty room from inside the door. Just gotta roll the window all the way up. Since the sheet metal is pulled out. Pushing it in should be fairly easy. If someone holds a flat dolly from behind. The door skin could be tapped back down. A big socket could be used on the lock area to hammer it down as well. It would need very little filler afterwards if time is taken to knock down the high spots.

Cutting the door skin from a donor, then cutting yours and welding /grinding is probably just as much work. If you got a welder thats an option. Just be aware of warping the skin. Pic for reference.


Last edited by 84 1LE; Jul 30, 2025 at 06:42 PM.
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Old Jul 30, 2025 | 10:44 PM
  #4  
aldrichg9's Avatar
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From: Terre Haute, IN
Car: 91 RS 5 speed
Engine: 305
Re: Door lock hole repair

Originally Posted by 69-er;[url=tel:6567958
6567958[/url]]I think it would be very difficult to get behind there with a dolly in an attempt to pick/hammer it to shape. My first thought is to find a donor door and cut out the lock hole, about 3" x 3", and weld it in. The costly estimate is from the repair, keeping it flat, filling and blocking it smooth and paint.

It won't be difficult to do but somewhat time consuming.
thanks for the reply.
the quote was just for the repair, as I’m painting the whole car
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Old Jul 30, 2025 | 10:46 PM
  #5  
aldrichg9's Avatar
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From: Terre Haute, IN
Car: 91 RS 5 speed
Engine: 305
Re: Door lock hole repair

this is what I’ve been wondering
if someone holds a dolly on the back maybe a right-sized socket could push the skin back down

Originally Posted by 84 1LE
I think there's plenty room from inside the door. Just gotta roll the window all the way up. Since the sheet metal is pulled out. Pushing it in should be fairly easy. If someone holds a flat dolly from behind. The door skin could be tapped back down. A big socket could be used on the lock area to hammer it down as well. It would need very little filler afterwards if time is taken to knock down the high spots.

Cutting the door skin from a donor, then cutting yours and welding /grinding is probably just as much work. If you got a welder thats an option. Just be aware of warping the skin. Pic for reference.

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Old Jul 31, 2025 | 07:34 AM
  #6  
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From: South Windsor, CT
Car: '89 GTA
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Transmission: T56
Axle/Gears: Borg Warner 3.70:1
Re: Door lock hole repair

Originally Posted by aldrichg9
thanks for the reply.
the quote was just for the repair, as I’m painting the whole car
If you're painting the whole car, I would not spend $1000 on a PDR guy to fix it. Hammer & dolly, little bit of filler.
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