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New Door

From 1978 Ford Bronco “Lula Mae”, documented by Indybronco.

18 photos
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1978 Ford Bronco - Got this intact door from a junkyard for $75. It was in much better shape than mine. It had slight surface and a few dents but the bottoms… 1978 Ford Bronco - The bottom is intact and that was really all I cared about. Note the aftermarket door panels. 1978 Ford Bronco - Minor rust. To get the rust out I sprayed Naval Jelly inside, scrubbed it with a small, stiff brush and sucked it out with a shop vac. Wash… 1978 Ford Bronco - To remove the panel start by unscrewing the handle. 1978 Ford Bronco - Next unscrew the window regulator. 1978 Ford Bronco - A lot of people forget to unscrew the door cups. 1978 Ford Bronco - Remember this is an aftermarket panel. The stock panels don't have these types of fasteners but the concept is still the same. Pry, lift an… 1978 Ford Bronco - Lift off the panel and you now have access to the guts. Here you see the window regulator which is fairly well rusted. 1978 Ford Bronco - Close-up of the window regulator mechanism. I'll scrub it with Naval Jelly and wash it off and it'll look new again. 1978 Ford Bronco - Here you can see where water collects at the seam and rusts the doors. A few passes with a wire wheel will fix the rust. 1978 Ford Bronco - Naval Jelly is great stuff. Spray on liberally, scrub it in real good, let sit for 20 min and go over with a wire wheel. Rust gone! 1978 Ford Bronco - After sanding with 80 grit. It had so many layers of paint that 80 grit didn't take it all the way down to metal. Still, it did get through… 1978 Ford Bronco - These holes will require fiberglass filler to close. 1978 Ford Bronco - The window moulding on this truck was so brittle that it just fell apart in chunks. Just use a flathead screwdriver and pry upwards. 1978 Ford Bronco - Next use a flathead screwdriver to pry loose the lower window molding. It's held in with clips so there will be an audible "pop" when you l… 1978 Ford Bronco - Close-up of one of the clips. 1978 Ford Bronco - Here's what the entire strip looks like. 1978 Ford Bronco - A car door is undergoing bodywork, with primer and filler applied, resting on a workbench.