http://www.chevelles.com/showroom/obseSSed/2004_1110Image0001.JPG This is the outer panel of my door. I wanted to post this with the other,(see other post about serious rust out), but I got booted off of my computer. I cut the rusted area out and want to weld a patch in. Should I just butt-weld the patch in as I have it cut or should I grind off the edges of the door where I have it cut out take the edges off and roll the patch around the edges ( see pictures). http://www.chevelles.com/showroom/obseSSed/2004_1110Image0008.JPGANY SUGGESTIONS FROM AN EXPERIENCED BODY PERSON. Or maybe I should just find another door

http://www.chevelles.com/showroom/obseSSed/2004_1110Image0008.JPG Here is the other picture of the cut out. This is the only other rust on the door

If another door is available, clean, and economical that would be the easiest way to go. Patching your original door isn't all that difficult. You should also remove the folded edge of the original skin where the patch will be. Make a pattern for the patch on posterboard or similar material slightly larger than the hole you've made and transfer to the sheetmetal that will be used. Make your patch and trim and shape untill it matches the panel's contour. Lay the patch in place over the hole and scribe along it's edge. Cut perfectly along the scribe line and your patch should fit the hole fine. The patch should include the extra 3/8-1/2" flange. After the fit is determined to be perfect, tack weld the areas where the butt weld will be, then fold the flange over with sheetmetal visegrips or similar to a 90 degree bend, then hammer and dolly the edges and finish your welds. You should end up with a good fitting, solid repair when done. Just remember to treat the inside of the patch or the rust will just start again. 3M's rustfighter cavity wax works well for treating the seams, cosmoline also works well. Hope I explained this OK. Bob

Put some rust encapsulator or something on the inside now while you can get at it.

Thanks for the info. I'll give it a shot on my pssenger side door as it is nowhere near as bad and I think I will try and find a driverside door:D