My goal for today was to figure out how to repair the top edge of the door. In the process I ended up removing all of what remained inside the door. Probably a good idea anyway, because of the welding that needs to be done.
I notice that with my new camera (Nikon 1) I take more pictures. I consider that a good thing. Why so many more? I'd say it is because of the larger monitor. I react to what I see, instead of hoping the one shot got what I wanted. Plus, it's fast. So, here are a lot of pics.
My first challenge was to do something about the reinforcing doubler behind the door skin around the door handle. I used a cutoff wheel on a die grinder to cut away the door skin, trying to leave the doubler intact so that I can reuse it. You can see some wounds where I hit it while working blind. There is some rust in the area, including behind the doubler, but I think it can be treated.
Had to remove some rubbery coating BMW put along the bottom edge of the door frame. It worked very well, except for where moisture got under the paint and rust formed under the coating. Removed with scraper and wiping with rag soaked with acetone.
Removed the few remaining plastic plugs that are used to hold the interior panel. Not sure how many the factory implemented, most of mine were broken.
Found this channel on the bottom of the door. Probably held a rubber seal; no sign of that.
This interior trim piece was attached by a single tiny Philips head screw.
Decided the door release mechanism had to come out. Note the one almost hidden bolt accessed through a hole in the door frame.
Removed the rear window lift guide. Two extra thin nuts at the top, two bolts at the bottom bracket.
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