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| Here is a simply silly idea that works...The cracks are
stress cracks from slamming the door. Also the cracks form from rust that works it's way
up from the holes punched to accept the window trim. As example on my passenger side door,
there were two cracks that formed. I had two Mitsubishi Montero doors that were
rusted out on the bottom and had been replaced. They were sitting in the Dumpster awaiting
the trash pick up. I was going to work in the CJ when I looked at the radius on the
doorsill and thought that it looked familiar. I pulled the Montero doors out
of the Dumpster and looked at the sill. It had the same radius. So I thought... could I
cut out the good sill and tack weld it onto the CJ door? Would it fit? Yes, it did fit,
like a glove! It took about 3 hours per door, start to finish, cutting out the Montero
door sill, to priming and finish coating the rebuilt CJ door, here's how I did it: |
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