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Inner side door shell damaged: possible to repair?

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Old Apr 10, 2009 | 07:54 PM
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Default Inner side door shell damaged: possible to repair?

The previous owner(s) before me weren't happy with the speakers that came with the car and cut into the door panel to fit what I assume to be larger speakers in. Also for some reason there is a large tennis ball sized chunk missing up top. I have looked and notice this half of the door is sandwiched to the outside portion of the door with some type of immovable epoxy resin or whatever.

Is it possible to cut the damaged areas away of the inner shell and repair similar to floor pan repair?
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Old Apr 10, 2009 | 08:19 PM
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Can you post a picture of what you're talking about. I've repaired pretty serious cracks in my door panel with fiberglass but filling in a hole may take some additional materials.
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Old Apr 11, 2009 | 11:57 PM
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Originally Posted by klkordzi
Can you post a picture of what you're talking about. I've repaired pretty serious cracks in my door panel with fiberglass but filling in a hole may take some additional materials.
Sorry for the late response. Here are the pics. I have no clue why that chunk is missing up top in the first pic.



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Old Apr 12, 2009 | 12:15 AM
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Is any of this ugliness visible when the inner trim panel is installed?
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Old Apr 12, 2009 | 07:53 AM
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Fiberglass clothe and resin should work fine. The tennis ball size hole could have been for a tweeter install.
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Old Apr 12, 2009 | 09:26 AM
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Originally Posted by AGENT 86
Fiberglass clothe and resin should work fine. The tennis ball size hole could have been for a tweeter install.

On the tweeters
They really hacked that up pertty good, you could also use some thin sheet metal strips and rivit them in.

Last edited by floridamale; Apr 12, 2009 at 09:29 AM.
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Old Apr 12, 2009 | 10:47 AM
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Originally Posted by tonylong
Is any of this ugliness visible when the inner trim panel is installed?
No, it's not but it's one of those things much like a big wad of grime lodged somewhere other people won't see it: I know it's there and it will drive me nuts.



Originally Posted by AGENT 86
Fiberglass clothe and resin should work fine. The tennis ball size hole could have been for a tweeter install.
Thanks, Agent 86. Now that you mention it there was an interesting hole pattern in the old door panel over the same area. But it was only on one door. I'm not an audio expert but seemed like a weird place to put one. Maybe they got halfway through the project and realized they couldn't do it.
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