OK - so I have fixed the door from it's fallen condition.

Firstly, I have an excellent panel beater friend who was of EXTREME assistance during the process.

Condition:
My L/H door was shot. The bottom hinge had punched through the door shell and caused it drop and not shut correctly. The R/H door was welded before my time and I can't tell you what happened there.

We took the door off;

Found some 2mm plate and 'shaped' it to the door - this involved tapping the plate and essentially punching the original shell in by 2mm so that the plate was flush with the shell of the door.

We then welded the plate to the door - IT WAS IMPORTANT TO KEEP SPRAYING WATER ON THE DOOR WHILST WELDING - this was done so that the paint didn't bubble

Grind down all the slag and make smooth.

Prime & paint

Drill holes and fit - bearing in mind the realignment of the door

There was much hassle in the positioning of the door and the attachement of it.


Super brief version I know.


Hope this helps.

Don't ya love smart lock !

I had the same prob with an xg it was the thin steel tearing behind the lower hinge plus the handle was stuffed , we put an XF door on and welded a plate on the door behind the lower hinge then had to swap the bit it latches to on the body to an XH part looks like s... Doesn't line up properly near the side mirror there's a gap in hindsight I would've repaired the original door behind the lower hinge the same as we did then get el handles , there is a post with a pic on one of the ford forums , looked good apparently the mech is the same I just googled xg door handles same as ?