Flat panel door

[Stormstyles]

I built a flat panel door that has a 7/8x7/8 square tube on the perimeter and also a cross in the center. I have it welded and also drilled holes in the center (like a cross) to plug weld this to keep from rattles. Well I must have gotten in a quick rush welding it. NOW I have plenty of warpage. I have read quite a few posts about on dolly and off dolly work but I have now spent the better part of 3 days trying t work it all out. But nothing! I still just have a bunch of waves. WHAT DO I DO? I aobut to throw it out and build another one. Can it be saved? If I purchase a slapper will it help alot better than just the hammer? I AM SO :?

[AdamMopar]

I'm sold on the slapper and shrinking disc, maybe someone here can give you more advice because I am just a novice at this. Adam

[Kerry Pinkerton]

I think you basically are at a starting over point if this is an automotive panel. There are VERY FEW flat panels in the car world. Almost everything has a slight compound curve. (A wheel is the easiest way to do that) That's what gives it strength and keeps it from oil canning. Even model A doors have a compound curve.

Interior plug welds just made it harder to fix because it locked the warpage in.

[Stormstyles]

This door is for a cover over the rear suspension that I have just installed in a hot rod. It needs to be really flat like the floor. Would you suggest on going with a thicker piece of material like say 14 ga? or how would you go about this process?

[Stormstyles]

oh yea you will have fun during the kruse auto auction. I have attended plenty of times. Used to live in Fort Wayne just south of auburn. If you get a chance you need to stop by the Auburn Cord Dusenburg museum also in downtown auburn. YOU WILL REALLY LIKE IT!!

[Dutch Comstock]

The way you got in trouble with your door cover is the way you welded it to the frame.You welded through the face of the panel with rosette welds and they shrunk the area of the heat affected zone.This shrinks the area around the spot wqelds and causes the warp on the panel. You will have to start over again and make a frame that you can fold the edges of the door panel 90 degrees and rosette weld the panel to the sides of the frame and the heat warpage will not affect the flat area of your door.You can also use panel bonding adhesive and have no heat shrink problems. Dutch

[FriarTuck]

A couple of well placed beads rolled into the panel will stiffen it up, and prevent rattles. And from my experience with Rods they usually look pretty good too!

[Ernie Ferrucci]

You can not weld in the middle of a flat panel without warping it. Time to start over, remove the warped sheet metal and cut a new one. You can brake bend the edges and weld the flap like Dutch suggested. The panel bond adhesive works great and if you glue the center frame it won't rattle. Whether you weld it or use adhesive, the panel will look neater with the edges bent 90 degrees over the edge of the frame. Hopefully you have clearance for that or you will need to reduce the frame dimensions by double the sheet thickness. I don't know how big that frame is but 20 or 18 gauge metal should be fine and will brake bend on a hand brake.

Good luck
Ernie F.