How To Replace A Doorskin
1. Two of the worst body sections of Cheap Street Chevelle were the doorskins. The original units had been smashed and were loaded with body filler. Rather than hammer out the door and re-apply body filler, we are installing a new set of doorskins from D&R Classic Automotive. Although the task looks difficult, the job is incredibly simple. Plus, with new skins in place, little or no bodywork is needed and the paint job will be much nicer. In the photo we begin the doorskin swap by removing the O.E.M. inner door panel. Then, we disconnected/removed the outside door handle. |  |
2. Using a high-speed, air-driven angle die grinder, grind through the outside edges of the doorskin that bend around the main frame of the door. | 
3. Once you've ground through the doorskin lip, grab the inside remnant of door skin with a pair of pliers. Then, twist/roll the metal remnant--breaking it free from the door. |
4. If you've completely ground off the doorskin lip and removed the "remnant," you should be able to pull the doorskin right off. If the skin doesn't come off easily, try lightly tapping the doorskin to dislodge it from the main door structure. | 
5. After inspecting (and straightening if needed) the main door frame edges, use an air hose to blow out any dust, dirt or leaves that may have accumulated inside the door. Then slip the new doorskin on the door frame. Make sure the doorskin clears all edges and sits flush on the door frame. |
6. Using a hammer and dolly, bend the edges of the new doorskin over the door frame. Don't just whack one area in a frenzied haste; rather, bend the edges over slowly and evenly to get the best hold and professional look. | 
7. With the doorskin edge properly hammered into place, begin tack-welding the doorskin to the door frame. After welding, use a high-speed grinder to smooth out the welds and panel area. |
8. Once the doorskin has been hung and properly welded, check to make sure the door-to-body alignment is correct. Often the rear of the door will sag slightly, indicating worn-out door hinge pins. Replacing these pins is inexpensive and easy, especially with the front fender(s) off, such as in our case. | |