Panel Replacement

We removed a subpar weld that failed Maryland safety inspection standards. 

We cut out and replaced the original metal in the lower corner (a common area for rust and damage on Jeeps).

We ground smooth and contoured the surface of the new metal. Here, the shiny, silver area is the bare, fresh metal where the grinding has occurred.

We applied a thin layer seam sealer along the edges where the new panel meets the old, olive-green painted body. This was used to smooth the final transition and seal the welded seam.

Rust and corrosion has compromised the structural integrity of the door's lower frame, meaning a simple surface treatment will not suffice. 

The extent of the rust meant that the affected metal had to be cut out and replaced with new sheet metal patches to achieve a proper, lasting restoration.

We cut out the severely rusted metal along the bottom edge and corner of the door and replaced it with a brand-new custom-fabricated section of steel (the prominent black metal patch).

Here the rest of the door has been finished and preppred, ready for the next steps. 

The white/silver area immediately surrounding the black panel is where the weld seam has been ground smooth. This grinding is a crucial step in metal finishing to create a near-seamless transition between the new and old metal, minimizing the need for body filler.