1968 Dodge Charger Restoration - Episode 35 - Door Skin Replacement

In this episode I do a full DIY replacement of the outer door skin. I start by carefully splitting the outer skin from the inner shell and to my surprise, NO RUST! I then clean and prep the outer skin for Lizard Skin application and UPOL copper weld thru primer. Last, I install the new door skin! Much easier to do than you may think!
In the next video I will be welding in the rear quarters for good! I'll also be leading the sail panels and doing a step by step DIY for you! All of the hard work needed to install all of the metal for this car is finally coming to a head! The end is in sight!
After this, I'll be doing a final install on the quarter panels and i'll be installing a US Car Tool Stage 3 Chassis Stiffening Kit, and rear spring relocation kit. That should be the last of the metal work!
If you'd like to support the channel, please check out our merch below! Also follow me on Instagram for more pictures of the build. @Rust_Bucket_Restos

[@Cat-Privilege]

Who knew that you could learn a thing or two about restoring a classic muscle car by watching Happy Gilmore. Chubbs would be honored. I wonder if Mr. Larsen had any words of wisdom that I missed.

[@mightymikethebear]

I was going to mow my yard but I watched your video instead. I hope it does not rain tomorrow, lol.

[@rustbucketrestos6511]

The yard will still be there tomorrow!

[@splender88]

Your work is some of the best I've ever seen. Fortunately for you, there are plenty of aftermarket parts for these Chargers if this were a less popular car you would have to fabricate many parts or spend a lot of time and money tracking down used parts.

[@malcolmhamilton5200]

"Nearing the end of bodywork". Shoulda seen your grin as you said that. This is one job I've done before, back in the 70s on my Austin mini. Both door skins and outer rocker panels(where the weird Brit jacking points are). Did it more or less the same way you did, except we brazed em' on(migs weren't around in numbers back then)and POR15 and Lizardskin hadn't been invented yet. Body lines were perfectly gaped, but one door heat warped it's frame and skin, twisting out at the bottom rear. My painter just laughed, opened the door put his foot on the bottom of the skin, grabbed the top and bent it right into place for me, first try. Nice guy. He sprayed it for fifty bucks, same amount I paid for the car. One cop told me it was the quickest 4 wheeled cherry he'd ever pulled over(magnet colour for cops). Great work. Neat tip on that expensive POR15. Following your every job with interest. Malcolm Ottawa Valley

[@rustbucketrestos6511]

Thanks Malcolm! I’ve had to do the same thing with doors. It’s amazing how much they will twist!

[@creeperman1791]

My dream car in life is Dodge charger 1970 only

[@rustbucketrestos6511]

They are out there!

[@keithhebert9334]

The progress that you have made on this car is totally amazing

[@rustbucketrestos6511]

Thanks Keith! 🤘🤘

[@seanposey9708]

You're making awesome progress dude! The Charger is really coming together. Great job! Keep up the good work and keep the videos coming! Can't wait to see this thing in paint. Also - glad you didn't spill your beer this time. 🤣😂

[@rustbucketrestos6511]

Me too!

[@chrissiebeneck3294]

solid tip about the 3/4 hole into the paint can, plug solution, ingenius!

[@rustbucketrestos6511]

Game changer!

[@307life9]

They also make a tool that looks like a can opener that crimps the flange over. Hammer and dolly work good too. Looks good. Love the vids.

[@rustbucketrestos6511]

Thanks! 🤘🤘

[@DScaglione.]

Masterful work as always. In the old days we only had our memory to look back on the work we did on cars. Now you/we can look back on Exactly every minute of time spent - which although may have been disheartening at times, is also a great part of the journey to bring this beauty back to life! I’m with ya every step of the way! God Bless 😎

[@rustbucketrestos6511]

Thanks for watching! 🤘🤘

[@joebacarella2829]

Very nice, I never seen a door skin done, so the skin comes with a 90 degree bend, and you fold it over with a hammer and dolly, that was some nice hammer and dolly work my friend, I would have the edges so wavy, I never was great with the hammer and dolly. I would have to use filler on all those edges and block, can`t wait to see you set all the gapping, well done for sure.

[@rustbucketrestos6511]

Thanks for watching Joe!

[@donsrestorations]

Great instruction of which I am sure will follow when it comes time for my 68 'ahem' mustang. Great job!

[@rustbucketrestos6511]

😆. Thanks for watching!

[@r.-m.d.]

Awesome, didn't even know that you can repair a car door like this! Excellent !👍👌👏

[@rustbucketrestos6511]

Makes it pretty easy to look brand new!

[@chuckeecheese162]

Nicely done, she’s looking really sweet.

[@rustbucketrestos6511]

Thanks Chuckee!

[@jamesfitzgerald6005]

Great work as usual. Watched this build from the beginning. Always look forward to the next video.

[@mana-ma-non3072]

Thanks for another great 👍🏻, haven’t seen anyone showing the door skin process. Honestly I think by the time ur done ( 100 more episodes) you’ll have more episodes on rebuilding a mopar than anyone has done on KZbin

[@rustbucketrestos6511]

lol I hope that’s a good thing!

[@jamesfitzgerald6005]

Great work as usual. Watched this whole build from the beginning. I always look forward to these episodes.

[@rustbucketrestos6511]

Thanks for watching James!

[@CRi-d1n]

I don't know if anyone has mentioned this, but for POR-15 cans, I've had great results placing plastic wrap between the cover and can to prevent a permanent seal. Also as added help, running a paper towel with lacquer thinner around the lip before placing the plastic and cover on removes any excess.

[@rustbucketrestos6511]

Best solution I’ve found is to drill a hole in the top and put a plastic cap similar to a thimble in it. Super easy to put in and pull out!

[@billmiller5075]

Great info , now I know how to separate the skin from the door

[@rustbucketrestos6511]

Super easy to do!

[@TheGreatest1974]

Awesome work dude. You are amazing. I have NEVER seen such a restoration in my life! You should be proud of yourself. 👍👍🇬🇧

[@rustbucketrestos6511]

Thanks man I appreciate it!

[@nigelbobinski5798]

I’ve always wanted to see this done. Thanks

[@rustbucketrestos6511]

Awesome! Hopefully I made it look easier than you were thinking it would be!

[@donsmith6045]

Yup that's how a door skin goes on

[@rustbucketrestos6511]

A lot easier than people may think!

[@tomswindler64]

Your tutorial on replacing the door skin is right on point,informative,simple to understand.great video.just keep doing what your doing.👍👍👍😎😎😎

[@rustbucketrestos6511]

Thanks 🙏

[@TheREALJosephTurner]

Another great installment! Call me crazy, but I'm really looking forward to the body gap video. (Who am I kidding- I'm always looking forward to ALL the videos, haha)

[@rustbucketrestos6511]

Right on! I’m excited too!

[@mazeurbanski]

good work she coming along nice

[@rustbucketrestos6511]

Thanks Mike!

[@KENNEY1023]

Another great video

[@rustbucketrestos6511]

Thanks Ken!

[@charlesdirienzo6422]

They make a pneumatic door skin tool FYI, work awesome

[@rustbucketrestos6511]

Yep super awesome!

[@lukeellis2961]

bit of motley crue in the background nice

[@rustbucketrestos6511]

Always got some music going!

[@scottkovacs7634]

Looks good maestro

[@rustbucketrestos6511]

Thanks Scott!

[@mopar4don]

The only thing I would do differently is before welding the skin on is to mount the door and check the profile alignment to the quarter and fender. Sometimes the skin needs racked to get it to fit the profile. To rack it you would hold top and bottom and push or pull to rack the door into alignment.

[@rustbucketrestos6511]

Once I get the car on its suspension and the engine installed I’ll dial in the gapping. They move around quite a bit once you get weight back into them.

[@dddiy6347]

You just like my dad was 🤗

[@mattt4666]

Great job as usual, I have learned a lot from you. Been watching since day one, looking forward to the suspension install.

[@rustbucketrestos6511]

Should be a good one!

[@DaPenceman]

You gotta paint 1 old door or just the skin, orange with an 01 on it and make a wall hanger out of it. It don't have to be perfect most General Lee's were beat to hell anyways

[@rustbucketrestos6511]

Haha I’ve thought about it! Would make a neat wall hanger for sure

[@trollingwithcookies3828]

Beautiful as always 😩😩

[@hubertbelden652]

Looks great buddy 👍

[@rustbucketrestos6511]

Thanks Hubert! 🤘🤘

[@samperras]

Door skins do my head in

[@rustbucketrestos6511]

Super easy!

[@danieltosti9421]

Bring me the horizon 😎

[@rustbucketrestos6511]

Love it!

[@michaelstanchina4530]

Had to go through this and gap fitting it afterwards. Looking forward to see what you learned about that. I struggled with it but eventually got it. Awesome stuff, keep up the good work!!!!!!

[@rustbucketrestos6511]

Thanks Mike!

[@GeekAndSon]

Amazing work!

[@rustbucketrestos6511]

😎🤙

[@YT-hr3xx]

One more step done! It is very detailed restoration! To be honest - I wouldn’t dare to do this way. I’d rather sandblasted the panel and fix the damaged part than change the door skin.

[@rustbucketrestos6511]

Replacing the skin makes it easy!

[@thevinylcollector3472]

awesome job man the door looks amazing

[@rustbucketrestos6511]

Sure does!

[@jasonmushersee]

looks better than oem already. you should see the factory booger welds my 68 mustang entire interior tunnel, front & rear seat brackets hidden under globs & more globs of seam sealer i'ld say the guy was in a hurry or had 10 thumbs. the wiring for tail lights turn signals was inside rocker panels no loom mice chewed them down to copper end to end that's why the fuse holder terminals were melted down like someone took an arc welder to them

[@rustbucketrestos6511]

They were put together pretty crudely!

[@pasqualetripodina5995]

❤ Nice 👋👌

[@rustbucketrestos6511]

Thanks! 🤙🤙

[@russclewley6945]

Really great video. Our doors are a little rougher. The shell has a few holes in them. We were lucky to find two doors that had all of the hardware and glass a year ago. Found them in Columbus. Planning on doing our doors this spring and summer. Hopefully we can get skins from AMD. Loving the series!

[@rustbucketrestos6511]

They are nice! Good luck with your build!

[@jamesmitchell6598]

Just something to think about before you finish all the metal work. Dodge put what they called torque boxes in front of the rear leaf springs for all charger with a 440 or 426 hemi. Just happened to think about that with the motor your putting in it. I know 318 cars didnt have them. Have a great day.

[@rustbucketrestos6511]

Yep, the Stage 3 USCT chassis stiffening kit arrived last weekend. I’ll be installing it in an upcoming video.

[@crbrepairmotorcycles6608]

You know the 1st car show you go to there going to nickname you Mr AWESOME because its going to be a awesome built car

[@rustbucketrestos6511]

Ugh I can’t wait!

[@MikhailScottKy]

I am generally surprised that you do not have some sort of media blasting booth for jobs like this inner door. If you do I must have missed it

[@rustbucketrestos6511]

That would make a great Father’s Day gift! You should tell my wife!

[@2koolchris291]

So I want to buy amd metal and build a 69 general lee clone with a newer charger base. All wheel drive with the 5.7 hemi. And I’ll get the dash and stuff to make it look close to original. It’ll be a race car/fun car and I won’t be worried about hurting a real 69 charger.

[@rustbucketrestos6511]

Very cool! A lot of guys do it on crown vics!

[@toms1348]

Nice work as usual. So, I'm guessing you'll lock in the hinges and striker, then check and adjust your gaps from there.

[@rustbucketrestos6511]

Yep I’ll get it close then lock it in. Panel gapping will come once weight is back on the car. Need to get the engine and suspension in before I do too much modification on the gaps.

[@toms1348]

@@rustbucketrestos6511, ah right, good point!

[@nerfbey5250]

Thanks for the good info, am curious though Why you don't clean n prep before POR..ing. Also just my 2 cents I have used POR on frames and spot uses in floors n such, but have not used it on large surface areas, as POR is a very, very, hard paint to the point of brittle not much flex.

[@rangercwgbear6352]

I’ve done door skins before about the same way most missed the quarters being welded on but I’ll back by thru see if I missed something

[@rustbucketrestos6511]

Right on!

[@ahmetsoylu1447]

kapının saçının alt tarafı çekiçler ken kapatırken demir kullanma demir yerine profil koy sağ sol köşeden mengene sık çekiçle bozulmuyor çekiçledikten sonra alt tarafı düzgün oluyor👍👍👍👍👏👏köşelerden mengene sık

[@ahmetsoylu1447]

under the door Only do

[@mssedmebich1621]

Way back in the 80's we used an attachment on the air chisel to put on door skins. Is that no longer a thing?

[@rustbucketrestos6511]

It is! There are also some hand held tools out there too that have nylon heads that squeeze the skin.

[@ultimatejay]

Wouldnt it be easier to drill the spot welds out and then bend tabs back and then remove door skin?

[@rustbucketrestos6511]

You could do that too

[@cameronshannon1789]

were do you get the tools and how much and i like the car i am a big dodge fan my grandpa has 1970 dodge charger with a 440 big block

[@rustbucketrestos6511]

You can get just about everything I use from Eastwood

[@kenny3217]

9 out of 10 restoration shops agree rocking out to Metallica is the only way to work. I prefer Master of Puppets but Kill em All was still a solid album. Seek and Destroy is probably the best song on that album too so nice choice.

[@rustbucketrestos6511]

Love it! 🤘🤘

[@narcosis9842]

Do you need to do the same to the other door or is it in much better condition?

[@rustbucketrestos6511]

The other one is in great shape.

[@markmoats5702]

I didn't know if you know how to exactly transplant the hemi in a charger but brycecold's channel just got done doing it with a dodge cornet it's the same platform as the charger

[@rustbucketrestos6511]

Yep! The Holley kit makes it easy!

[@andrewbaluk1663]

do you deactivate the rusy in any way or do you just por15 over the top?

[@rustbucketrestos6511]

I use a rust converter from Eastwood. You can also POR15 straight over rust too

[@barrydevlinred]

Looks good mate tho is it bad that the black on copper colour contrast is doing it for me he he

[@rustbucketrestos6511]

It looks good!

[@davidbarnes7170]

At 22:54 is that highly suspect sertonia music video in the back ground

[@rustbucketrestos6511]

Yep!

[@jamesmitchell6598]

I know theres really no other way to do it but the door moving everytime you hit it would drive me nuts

[@rustbucketrestos6511]

Doesn’t really bother you when you’re doing it!

[@indigojewsnap7307]

Hallelujah Sweet Jesus. Thought it was only me that couldn't get a POR lid off.....after putting the lid back the 1st time, I have broken crow bars trying to get it off the 2nd. Last can I took the lid off with an angle grinder and destroyed the blade, what do they make them out of?

[@rustbucketrestos6511]

Lol yep. It’s when the coating gets into the room of the lid where you are in trouble. It’s basically a chemical bond and every time you take the lid on and off it gets worse! Drilling a hole makes it a cinch!

[@stevenduering7155]

Hang the door on the garage wall.

[@rustbucketrestos6511]

I like your style!

[@ShadeTreeGeneralLee]

You wanna sell that skin

[@rustbucketrestos6511]

To use as a wall hanger?

[@ShadeTreeGeneralLee]

@@rustbucketrestos6511 yep

[@ShadeTreeGeneralLee]

@@rustbucketrestos6511 I think it would look good painted like the General door

[@rustbucketrestos6511]

Nooooo!

[@ShadeTreeGeneralLee]

@@rustbucketrestos6511 so that’s a Nooooo sale?