How to Fix a Rusty Ford Model A Door Part 1 - Rust Repair

The roadster that’s been hanging out on the frame table in background was brought to Matt for some rust repair. While the body is in decent shape for its age, there were some poor repairs started and the body was moved without proper bracing. The doors hardly fit and need a lot of work. Today we are going to remove the skin from the door and see what needs to be done to get the door latching correctly. We will also be fabricating a new lower portion of the inner structure as it is rotten and badly in need of repair. In part 2 we will be attaching the new door skin and making sure all of the body lines match!
Get 15% Off Your Eastwood Order With The Coupon Code ITG15 At Checkout * Some Products Excluded -
Tools Used -
Eastwood Quick Change Worklight System - www.eastwood.c...
Eastwood Elite Deep Jaw Shrinker/Stretcher - www.eastwood.c...
?srccode=1VD5533
Eastwood TIG 200 Digital Welder- www.eastwood.c...
Eastwood True Color XL View Welding Helmet- www.eastwood.c...
Eastwood 2" Surface Prep Tool - www.eastwood.c...
Wanna send us something?
Iron Trap Garage
PO Box 6
New Berlinville, PA
19545
Amazon Wishlist - www.amazon.com...
Matt's Instagram - @irontrap - / irontrap
Mike's Instagram - @mhammsteak - / mhammsteak
Email us - [e-mail]
Get Your Iron Trap Merch Here - irontrapgarage...

[@RichieCat4223]

I like others would like to see more of this type repairs. I'm sure there are home hobbyists that could learn from it. Thanks.

[@IronTrapGarage]

Thanks for the input. We’ll keep showing these repairs as I tackle them on this car.

[@freddiebates5539]

What if I don't say anything.

[@Ismael-cq9ye]

I agree completly with you!!. Regards from Argentina!

[@RichieCat4223]

@@freddiebates5539 Meh !

[@RichieCat4223]

@@Ismael-cq9ye Hope things are good for you with your health.

[@harveymushman8209]

Nice work please do more . That’s one thing you never see a tv car resto show do.

[@IronTrapGarage]

I agree, we try to balance the tech videos with the “entertainment value” videos. I’m glad these ones bring some value for viewers!

[@lldrabek4569]

retired body man of 23 years can come exactly where your coming from out of body work for 22 years, retired now would like to get back in to after watching your videos so keep them coming. good job thanks so much. love this kind of watching

[@IronTrapGarage]

Thanks for watching! I’m just an amateur hot rod enthusiast. My way isn’t the 100% correct way I just like sharing how I get the job done. I hope I don’t make the seasoned vets cringe with my work haha.

[@retiredhappy466]

I own a 1931 Model A Sport Coupe that needs a little rust repair work. After seeing what was involved with this Model A Roadster, I will sure be careful when I pull the doors off. Love this fabrication stuff.

[@IronTrapGarage]

Thanks for watching!

[@mma88cms]

This is what the guys doing this want to see! No one needs another "i built a car in a week with 5 gallons of bondo". Your contents always been great and this makes it 1000% better. This is awesome, thank you so much!

[@IronTrapGarage]

Thanks for watching! I’m still a mortal and use body filler. But trying to show how to tackle some of these repairs that would scare a beginner. Thanks again!

[@62_C10]

door bottom looks great Matt

[@IronTrapGarage]

Thanks Bob!

[@philvanim4888]

Thanks for showing some of the "little stuff" that is part of completing even a non-show car. These can be project stoppers that keep you out of the garage for a while. (Don't ask me how I know). Your presentation style helps eliminate the intimidation factor. You keep at it until you get to an acceptable result. Not perfect. I appreciate that!!

[@garypowers4886]

Cool to see you repair the door instead if scrap it. Nice metal work.

[@IronTrapGarage]

Thanks for watching!

[@jamessheets9205]

I really like this type of video. It's doing little projects like this that add up to get a car done. Too many people think it happens like it does on TV and in seven days a shiny car rolls out of the shop.

[@IronTrapGarage]

Thank you James! We’re trying to keep it real with our stuff and show the good and bad and fun and unfun parts of the process!

[@douglasjucoff6476]

Matt you are doing a good job I have done sheet metal & fab work for 40 years

[@andrewkiwi1]

You made a good job of that inner door panel. When it was built, what was its life expectancy 15 years, maybe. 80 years later Matt comes along to makes it like new again. Its a wonder there's enough of it, to find something to weld to. I wish when the start manufacturing replacement panels they might once in a while actually compare them to an original. Sometimes they they just don't fit well at all which makes it twice the work to fit it.

[@thebeatnik5135]

You take me back to the 60's when I work with my grandpa Thank you - A.K.A. The Beatnik

[@IronTrapGarage]

Thank you so much for watching!

[@53chevsled]

Great video, I think everyone can learn from videos like this and enjoy it at the same time even guys that have been doing this sort of thing like myself for nearly 30 years still learn new techniques and methods that make it an easier or cleaner job , great stuff, cheers from down under Tasmania Australia 🇦🇺😎👍👍

[@IronTrapGarage]

Thanks Adam! I’m no pro, just an average guy in the shop that learned by doing and I’m always learning every job. I figured sharing my way of doing this stuff might help others or take some of the fear out of tackling a job like this! Thanks for watching!

[@53chevsled]

IronTrap Garage , I look forward to every video and I’m no expert either I’m a motor trimmer by trade but build 20’s and 30’s cars in my spare time and lately 50’s stuff , I had to learn how to do the same sort of tasks by trial and error if only there was something like your videos back when I started it would’ve made life so much easier and more fun , the old guys over here that have been doing it all their lives don’t seem to like to share their knowledge and skills and to have guys like you share your skills is awesome and I’ve learned a lot of new tricks watching these videos, can’t wait for the next one, thanks for sharing, cheers

[@handyhippie6548]

perfection is the enemy of good enough. on something over 100 years old, that has been thrashed, and rebuilt multiple times, good enough is the best you can do sometimes. thanx for showing how to get it to work. most times, that's half the battle.

[@IronTrapGarage]

Thank you for watching!

[@brianturner8477]

It is really helpful when you explain, as you have here, what and why you fixed things.

[@IronTrapGarage]

Thanks Brian glad it was helpful!

[@mattomon1045]

I'm glad that you are teaching how to reskin a door . Now they just rip off the door and replace it wit a new one. so thank you for teaching.

[@angelalogan1468]

Love the fabrication videos, keep them coming

[@IronTrapGarage]

Thank you for watching!

[@flyfisher1141]

Agree. Love seeing this kind of work. It’s more educational than the TV shows with no detail on how the guts go together.

[@charlesfrazer1166]

I like this kind of stuff!

[@minbannister3625]

Is your middle name Kaiser?

[@terrykeithley6183]

Matt, these are the type of vids that really help. Thanks very much, Terry

[@richardsiddon610]

Good to see some of the bread and butter work Matt. Giving the new guys some pointers and letting folk know it isn’t all about polishing dollars onto a project.😁 Thanks and take care.

[@IronTrapGarage]

Yep! Just takes some hard work and patience most times! !

[@billmaguire6216]

I restored a 29 roadster back in 69-70. My good friend and street rodder suggested I pull the sides of the body in until the doors fit at the bottom, then make a fitted I" square tube welded in place underneath the surround to hold it. The owner didn't want that and the doors still stick out a little at the bottom. My friend explained to me that over the years of use the body panel tended to move out at the top. You probably already know this? The "Free Tee" Thanks for sharing.

[@IronTrapGarage]

Thanks for the tip Bill

[@Ecosse57]

the way you explain things and mike edits the video you guys succeed in making educational stuff that avoids being tedious to watch.

[@IronTrapGarage]

Thank you so much for the feedback we’re glad they come together and are fairly easy to watch even if the topic is a bit “boring” to some

[@SteveTheFordGuy985]

Hello Matt, I sure did like this video with you showing in-depth the repair to the door and how you go about finding the problems with fitment/alignment. Thanks, Matt.

[@IronTrapGarage]

Thanks for watching!

[@colingregson7690]

thanks for pointing out that after market panels often need "help" to fit !! alot of people gloss over this and gives inexperienced folks the impression you can "just" fit the parts straight on ! thanks for showing what its like to do this kind of restoration for real !! i for one much appreciate you showing what its like doing this sort of think in the real world !! keep up the great work !

[@brianlohr3412]

thank for showing what the door was doing and telling what u were going to do to fix it !!!!!

[@IronTrapGarage]

Thanks Brian! I skip over this stuff sometimes but I figured I’d show it for the viewers that are into the technical stuff

[@jimmycostanzo5119]

Nice work Matt.

[@IronTrapGarage]

Thanks for watching Jimmy!

[@ryangrimes7083]

Hey guys, love the show! My 17 month old son and I watch the show religiously and have since he was born! I have a 31 Model A Coupe that has some pretty crude patches put on it. Like a piece of metal with screws in it!😳 It seems pretty solid but it is a total basket case. I have minimal body working tools and plan on replacing all of them with patch panels. So I’d love to see more of this type of stuff that the average guy would be doing in there garage.

[@IronTrapGarage]

Wow that’s great you’re raising a gear head from day 1! Glad you enjoy these videos ill definitely try and do more!

[@rogermiller8262]

I like how you sanded thru the edge of the door skin to remove it. I probably would have tried to peal off the wrap around lip. Much cleaner and less stress to the part. Sweet! Thanks!

[@IronTrapGarage]

Yea I learned that after spending hours drilling out spot welds and wondering why the heck I spent all that time saving a part I was gonna junk! Haha. Thanks for watching!

[@raylarkin5004]

Yeah, that was cool!

[@andrewslagle1974]

I have seen guys grinding the edge to remove skins on modern cars as well .

[@steveanderson5888]

I would love to see more content like that stay safe brother do not get that virus

[@tomrichardson2099]

Matt, really found your door skinning video instructive. Thanks for that. There are many more backyard restorers out there than experienced, I am sure. I know I learn a lot from your videos. I have been fooling around with cars for more than 50 years, but enjoy learning, nobody knows it all.

[@fitzeesfabrications]

Model A body's took shimes under the cowl for aligning the door. Hinges were mount to the cowl and aligned to the cowl. Then to aline to the rear section you you shim the two front body mounts to get the angle you need. Nice repair on the door. Well done.

[@IronTrapGarage]

Yep I’ve seen those diagrams before. I figured I’d fix the body with no shims now so it allows for future owners to shim the body as it flexes or moves and twists over years of driving. Figured since I’m starting a ground zero I’d do it with no shims. Gives room for shims when The owner does final assembly. Thanks for the tips!

[@57Banjoman]

I've done a lot of re-skinning over the years, and wanted to say that you did a very good job explaining the steps involved-well done!

[@IronTrapGarage]

Thank you I’m glad it was easy to understand but also still relatively correct in how others do it!

[@atomrocket2785]

Very informative, and awesome work

[@521farmer]

Amazing how much work is needed to make this work and how ya can do it with what you have thks for sharing good pointers within a budget like most have do it right make it happin ya got this and thanks for sharing your project with us keep them coming ya make it look easy

[@gordonhenagar6652]

Liked the video and how you show the complete struggle it takes to get something right

[@scotth9881]

That really turned out well. I think these types of videos are great.

[@kenfoss5590]

back to metal work ...good to see

[@billmaulding4042]

ITG- Thanks for sharing your knowledge and tips for metal repair. I always learn something in these types of videos that you do

[@philipvaldez9505]

Great stuff! I often wondered how metal workers replaced rusted door bottoms and today I learned a lot! Amazingly the door looks brand new!

[@IronTrapGarage]

Thank you for watching Philip

[@garretlee83]

This is the type of stuff I need to see to get me working on my 32 pu doors!! Thank you. I get so focused on making it look original that I get overwhelmed. When all I want is a primered hotrod. It’s Hard to tell yourself that you don’t have to fix every pin hole.

[@IronTrapGarage]

It definitely depends on the car, your expectations for the car, and the end value of the car. Aaron would have far more into the body than it’s worth if I had to fix every tiny little imperfection. I’m making it “nice” but not going overboard. Those tiny little pinholes will easily get sealed when we coat it all and won’t be a problem. You’d be surprised how many nicely restored cars have corners like that cut.. they just don’t lay it all out for everyone to see like I do. Thanks for watching!

[@joedyer8824]

Door looks great Matt after market always fits a cording to the manufacturer ha ha can't wait to see the next video

[@timwarlick9132]

Seeing someone else do it helps give me confidence that it can be done. Sharing your technique gives this video a lot of value. I’d like to see more vids like this one

[@IronTrapGarage]

Thanks Tim! We’re glad it was helpful!

[@minbannister3625]

I like this content. How you approach a repair is the best part. Even if you have to change the plan during the work your explanations are very enlightening.

[@IronTrapGarage]

Thanks for watching!

[@ndeep45]

T shirt acquired... glad to hear its running under it's own ignition system. COOL! Braising work is fun.

[@frankjones4950]

Plus 1. I have experience doing this work (read I'm old) but i always like watching other people's methods. Like Gene says "every day is a school day"

[@drscrib99]

Thanks for being there Matt.

[@NanDo-fm2cg]

Matt thanks for the video, these are really helpful for people like me trying to do rust repairs.

[@IronTrapGarage]

Thanks for watching!

[@evilamish]

These videos give me the motivational that I need to work on my m715

[@PaulSmith-oy6fc]

Great post always appreciate the "hands on" fabrication / welding sessions and you taking the time to explain why things are done in a particular way. This helps a lot of guys out there who have never had formal training in these skills and are learning as they go.

[@IronTrapGarage]

Thanks Paul I appreciate the feedback!

[@dwighttravis5484]

With me being new to rebuilding cars, I loved you showing me how this sort of things are fixed. Please continue to so how these type repairs are made!!!!!!!

[@guillermonieri4203]

Super nice video. Very informative. Thank you.

[@pauljohnson4846]

Watching you and cold war motors its amazing to see you both work metal like that .making panels i know its hard but you guys make it look easy. Nice job.

[@IronTrapGarage]

Thanks for watching Paul!

[@TheMot616]

Yes, Repair Fabrication -Keep them coming and thanks for the videos during this quarantine ✌️

[@IronTrapGarage]

Thanks for tuning in!

[@jerrylong381]

Hey Matt, So far I haven't found any of your stuff that I don't like. Keep it coming. You're doing great.

[@IronTrapGarage]

Thanks for watching and for the feedback!

[@sohc13]

This is the kind of stuff i really like , Thanks Matt

[@raylarkin5004]

Matt, i do indeed enjoy this content. And while i don't have a model A, it totally applies to door hinge and door fit problems on my 69 bug. And also on my old Chevy driver door hinge and fit too. The bell between my ears dinged the moment you showed that saggy hinge. Thanks, i always watch but really got fed this morning. 👍

[@olronholleran1310]

I think there are very few people that can do the work you do. Gramps

[@helltrucker6667]

All the little details and hours put in is why I'm here and not watching the heavily edited shows on TV. There are plenty of other channels to go to for time lapse montages so people can see the burnout in a 15 minute video. I'm here to learn as much as I can. #TalkNerdyToUs

[@IronTrapGarage]

Thank you for the feedback! We try and balance the videos between those that are more on the entertainment side and the more technical. I thought this was a good time to show the more technical stuff. I’m sure some people won’t enjoy the drawn out talking in these but We can’t please everyone!

[@helltrucker6667]

@@IronTrapGarage Huge thanks to Matt, Mike, Andrew, and everyone else in the 'Trap' Yall do an amazing job. Even before this crazy pandemic thing going on, i wish i had friends in WNY who were into a collective participation like your Sunday Service gatherings. I see cars every now and then around Buffalo, NY. But in my experience, everyones a little distant. Keep on doing what you're doing. And if someone finds this stuff boring, theres other projects they can watch. ☺

[@29roadie17]

Good stuff! This is the stuff every guy has to tackle if they find an old original car. Thanks for doing it Matt.

[@IronTrapGarage]

Thanks for watching!!!

[@dannyplanck6498]

I do like to see the side projects. Keep up the good work!

[@themightyrev5228]

Matt the more you show these "nuts n bolts" videos the more I wish you had a few dozen more to watch. It might be cool to package a few of these into a playlist eh.

[@IronTrapGarage]

We could create a playlist for sure! We have ones started for each project, but there are some videos that could be a good general rust repair playlist

[@mamaleighcase1569]

I'm not a Auto Body tech, but video's help me to understand body work & how to do it right. Welding is my thing...so I understand where you're going with this. My new knowledge is due to KZbin & friends I have nade along the way. Keep up the good work!!! Aloha, Mama Leigh

[@johnalbrittonsr]

Making patch panels are great to learn because nearly all doors fender Cab corners etc require these repairs

[@380.motorsports]

Very helpful! I was hoping you would do a more detailed video on door fit and especially latch adjustment. I’m have a similar issue on my ‘29 roadster doors getting the latches to work properly and this video was perfect. It gives me more ideas of where to look at hinges and the latch to make it fit better and stay latched. Keep putting these type videos in your mix.

[@IronTrapGarage]

Glad they’re helpful Bob! Thanks for watching!

[@garyvs.carsmore4607]

I love this format! While it’s nice to see work on these projects, it’s even better when you take us through your mindset. I was welding tonight and thinking about what I learned from you from the 30 roadster rear corner video you did. Thanks. Gary

[@IronTrapGarage]

Thanks Gary!!

[@georgeparker9977]

Great work!!!! Back in the day, before replacement door skins were available it was common to (1) grind off the skin, (2) straighten the panel, and then (3) edge weld (gas) it back in place. Lead no plastic. I seem to remember the first plastic here in New England was "PERMEND" about 1957 or so. Great to see you are caring on the metal working tradition.

[@pappabob29]

Good stuff!! Definitely need aa much of this "stuff" as possible. This part is every bit, if not more, important as attaching the skin. Please don't forget to illustrate how the final attachment of the skin is used to determine and "lock" the "shape/twist/alignment" of the door to the opening.

[@IronTrapGarage]

Thanks Bob! I’ll be showing that part in part 2!

[@stevekelley1536]

Thanks for sharing this. I have a model T door that I have to do. You saved me a bunch of headaches.

[@deweywright8423]

I've been working in body shops and mechanic shops my whole life and I love watching these types of videos! I'm sure you just saved some guys sanity in their home shops. Got to do this and a lot more to the two model A's in my shop at home.

[@chrispiazza7487]

Nicely done Matt! I like your finger switch! I'm used to the foot pedal, I've been welding with one for 40 years and can't (wont) change now .

[@robertbiesiada7479]

Yes awesome! More technical stuff! Love it!

[@IronTrapGarage]

Thanks for watching!

[@willsee1822]

All your guy's content is great. Look forward to watching as I work on my olds powered A.

[@goosecreekgarageh.s.7333]

Like the fact that you mentioned about how long you had been working on that one section the videos made things look like they don’t take that long to do. looking good those model A doors fit like crap from the factory

[@frankhartranft2133]

Good video. Craftsmanship rules.

[@IronTrapGarage]

Thanks for watching!

[@chriscoccia2353]

I always enjoy your metal fab repairs, thanks for the videos

[@IronTrapGarage]

Thanks for watching!

[@dennisc.1189]

Matt, awesome video. I know I heard that door says my skin is feeling better already.

[@johnapel2856]

Very helpful. Well done. Thanks!

[@IronTrapGarage]

Thanks for watching John!

[@darrellrogers3511]

love it! More content like this please!

[@onehotpinto]

I enjoy the more mechanical aspects of these projects so by all means show more. I think that the main reason I like the KZbin programs better than TV is who gives a crap if "Kevdog" won't share his cookie? I want to see how they arrived at the modification they made on a particular panel. Keep up the good work and I'll keep watching.

[@IronTrapGarage]

Thank you we’re glad these real life repairs are helpful and interesting!

[@randynaser7288]

Great video and it was helpful to see the process of building the inner door structure. Thanks and stay safe!

[@nealpurdy1202]

Love the video Matt! Its very informative. Thanks Stay safe!

[@IronTrapGarage]

Thanks for watching!

[@russb3816]

Matt, you are an artist with your fabrication skills. I'm amazed every time I watch. Thanks for sharing your tips and talent.

[@jamesmartin4466]

I'm trying to tackle the same issues on my 29' Roadster and struggling with getting a decent door that will close and fit semi well. This video helped me alot, thank you

[@stephaniemoon5480]

That's a great video I'm doing the same type of stuff to my 31 roadster body looking forward to the next one

[@IronTrapGarage]

Thanks for watching!

[@BoxcarsGarage]

Completely enjoyed this video...all are great! But the task execution of this repair is exactly what I need to be focusing on. Thanks. As a caviat, I was amazed to see that you still have the guard on that grinder.... it's new right? I'm more used to seeing ITG living on the edge (guard free)....

[@IronTrapGarage]

Haha I leave the guards on the cordless grinders because they get thrown around so much I end up breaking the cutting wheels or sanding discs. Nothing I do has any rhyme or reason haha

[@ajperotti2551]

I see the new IronTrap Garage How To videos coming soon. $19.95 and your rear view mirror get you one. LOL. Keep them coming Matt. Nice work. I believe watching this type of video takes the anxiety out of the DIYer wanting to attempt this type of repair. Thanks again. 👍😎

[@jusike633]

videos like this most pleasing , as they show jus how much time and skill it takes, and ways to get them dun. I myself enjoy them very much. keep um come n.

[@larryrothrock4488]

Yes it is nice to see all the work you do on these great builds Cudos on your welding

[@jamesbrunker8377]

love old type model a

[@keithlalonde4308]

Hey Matt run a vertical down mig weld down the inside of the panel then come back and fuse the outside with the tig torch the mig weld provides a backer.

[@robertwayne2004]

Thanks for sharing your build a friend from Canada Rob ✌

[@esteysgarage3949]

Nice! I know that is a lot harder than most people realize.

[@johnsecord9697]

Thank you, thank you thank you! Both of my roadster doors are rattier than the one you are working on. This stuff is really helpful. Do lots more. I recently bought a set of Eastwood offset bead roller dies and by making two offsets the correct distance apart, I used a half inch bead roller male die and a skate wheel to put a nice arc between the offsets. I used the roller like an English Wheel to make an arc that was bigger than the roller. It takes patience, but I made a 7/8” bead with a 1/2” bead roller. I did not understand the skate wheel until you explained it. Thank you!

[@IronTrapGarage]

That’s awesome John! I’m glad you were able to build upon what I showed! Great job!

[@doug.patterson4732]

i love it that you make alot of the parts by hand you are talented

[@samuelsmith5098]

I enjoy all your videos but this was especially cool for me as I have some doors that need work. I was just going to dive in, and I have fab and machinist background but this helps unify my approach. Recently rescued a 66 D 200, did the first start where I found it and drove it home. Just that was worth the 500 I paid for it. It was less than 2 miles from my place and I never got over 20 (no brakes) but very satisfying. Brakes are coming along, tires are next. Has gigantic (and ancient) bias ply LT 235/85 R16.

[@leestimson12]

Definitely love to watch the process. I have always really enjoyed watching a craftsman at work and when it comes to old cars two thumbs up. More more more.

[@jeffsnyder2051]

Thanks Matt ,you are a great teacher!

[@kenswitzer4133]

I seem to learn something every time I watch your videos.👍🇺🇸🤙😃

[@redgoatgarage6880]

Love all the videos , gives me inspiration for working on my own ride, and definitely helps us all get through the quarantine, thanks Matt

[@IronTrapGarage]

Thanks for watching!

[@BrianSmart1959]

Thanks Matt! Interesting to hear some of the back story on how the car got to the way it now. Bullet Holes!