I don't know if there are any pre-formed patch panels out there. I find that those that are available, all need some finish forming to make them work. It's easier for me to just make the panels myself. Then they fit like they should. I've formed the lower parts of the door shells and have one tacked into place. It's very important to keep the door fitting to the opening during the rebuilding process.
Bolting the door on and taking it off again will happen numerous times during the process. If you skip that process, it won't fit in the end. Trying to bend it into shape at that point will result in some ugly distortion and a completely disastrous finish product.
After I am finished welding the shell together, I will check fit again, and then at point I will form the outer skin which I have already made pattern for. The skin will get tacked into place, joining it to the existing skin, and then the whole skin will be removed from the shell at the bottom of the window opening.
I'll be showing the rest of the process in the next posting. Stay tuned.
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