Bottom of Driver's Door Post Repair

 Need to restore the bottom door post structure which was rusted & cut out during the rocker panel rebuild 

 I began by fabricatingthe outside radius of the original door post. Not OEM but will be structurally sound and no one will see it!

Once I had the piece shaped and located where I wanted it I began tacking it in place, working the curves & angles to blend with the remaining existing structure. 

Next I made up a paper pattern of the top piece of sheet metal...

 ...transferred it to some sheet stock...

...cut it out....

...formed it ...

....and tack welded and formed to shape...

Piece is finish welded...

 ...and welds are ground down.

Not pretty but bomb-proof!!!