My 71 has begun to get cracks in the metal at the top, forward part of the doors, right where the window frame and the horizontal molding meet. Anybody else ever have this occur? What would be the best fix, short of replacing the entire door?

Is it possible it could be old rust repairs coming through?

I think I read something a while back about water sitting at that point on the door, getting trapped at the forward end of the horizontal moulding

I have the same problem on my drivers side door...

This is what it looked like when it came from the sand blasting company

I have seen that several times. That is a weak area on the door structure.

Will

Stress fractures. I've seen them in other makes and at the same location. Weld them closed and hope for the best.

May be able to TIG them back together and be ok for a few more years. I had them on my 69 Chevy truck. The door starts to sag on the hinges and that is where the stress shows up.

I've got that on my drivers door. Doesn't seem too uncomon judging from this post. If it is a stress crack, then mig, tig or arc welding probably wouldn't be the best bet because the weld is harder than the surrounding metal. This would help it to re-crack. Oxy might be the better option as the weld is a little softer.

Any experts out there as I'm just guessing?

Interesting thread,

I have no stress fractures on my doors, however, when I close my driver's side door, the metal 'POP's as the closing or opening motion is about halfway through. Could this be the doorskin that has deformed over time and is poping in and out of place ever time is moved?

anyone else have this problem or know how to fix it?

somecreep, do your doors sag AT ALL? it could be from a misalignment. I would check the alignment closely.

Interesting thread,

I have no stress fractures on my doors, however, when I close my driver's side door, the metal 'POP's as the closing or opening motion is about halfway through. Could this be the doorskin that has deformed over time and is poping in and out of place ever time is moved?

anyone else have this problem or know how to fix it?

Try greasing the door hinge tensioner that is designed to hold the door half open. Sounds like that might be the cause.

Most of the time, this damage to the door skin is caused by improper adjustment of the window frame. This is especially true after installing new door weatherstripping. Some complain that they have a hard time closing their doors, or have to slam the door to close it. To cure this, loosen all the window frame bolts, adjust the door to fil properly, then adjust the window frame to fit properly. If the top of the window frame is adjusted too close to the weatherstripping, it will act as a lever and apply great force on the outer door skin where it meets the inner portion of the door, resulting in the outer skin pulling away or spliting. This can effect either the top front or rear of passenger or driver door.

Good tip Ken! Thanks, as I am about to change my rubbers on the doors...this tip probably saved me further cracking (doesn't appear as though I have any now)....

;-)