'Cranky'(the '25 coupe) still has a leaky passenger door... The bottom of the door -the metal parallel to the ground; the area with the drain holes- is good for Sunday, being 'Holy'. The door skin itself is very good, but the center/inner-door angle support is also half gone. Have checked with Lang's & Snyder's - "Not Available". They suggested contacting Howells's, which is not always successful. Without destroying another perfectly good door (or doing a complete door replacement), any suggestions? Should I just resolve myself to making a new panel? Thanks.
Get some sheet metal and make the parts yourself. You can clamp the sheet metal between two pieces of hardwood with sharp corners then use a hammer to fold it over. On the bottom of the door remove the rust one way or another then cut a piece of sheet metal to fit and generously JB weld it inside the bottom of the door. Drill new drain holes.
A little creativity, and you can usually make your own patch panels in about the amount of time it would take to unpack ones you ordered through the mail. I have, over the years, made some rather complicated repair panels for doors and fender wells.
If you do decide to make your own panels, David Gardiner in the UK has a very good DVD showing a variety of techniques with only basic hand tools.
There is an intro/ad for the DVD on YouTube:
Andrew, the basic techniques in the video are very appropriate. 'Kinda figgured' I would be best off with making the patch myself, but never thought of using a sand bag. Having a 36" metal-break, the 90 degree bend won't be a problem, just the curve of the door skin. Do wonder though if anyone has dealt with that inner-door angled support piece? Guess it's "putz time" and experimentation....