As you can see, the bondo job by Stasek Chevrolet was a total hack. Any options here besides replacing the door? That bottom rivet hole is fully broken! 😡

 

no picture. bondo wont work. i have read of guys using fibrerglass and a steel washer inside the glass to reinforce it

 

Check again, I see the photo...

The design here is ****, the engineers should be shot, there should be metal reinforcing this entire rivet area! I am leaning at replacement at this point...

Anyone have some good leads on junkyard body part search sites?

 

one on my passengers side we had to use bigger rivets to make it work ,it is a poor set up ,i love the cars .that had one like a mini starter,you could rebuild them or in most .cases just relube the motor put back in was 20 mniute job .on an old van i had ,these.are stupid set up ,i have mine done bye a guy who knows the cars ,i would love to just go back to old roll ups ,i am not sure i hear someone say they sell a .kit to make them manual again dont know how hard they are to find ,or if its like from fire bird ,but i have hear of guys doing it

 

Epoxy in a flat pc of metal and drill it to size. 20 minute repair.

 

These composite materials are very easy to repair. The "secret" is in using fiberglass cloth as reinforcement and some marine-grade polyester or epoxy resin. Buy the fiberglass cloth anywhere. You should be able to get all of it for under $40.
WEST MARINE Fiberglass Repair Kit | West Marine
I repaired some cracks at the hinges on my 98 door. I bought the more expensive epoxy because it had to be strong enough to not crack again. Very easy to sand and patch the original material. Since it won't be visible, you don't have to paint it. Overlap the glass cloth at least 3 inches around the hole or slot (3 layers minimum), after filling the hole with a paste made from mixing glass fiber cuttings and resin. When done, re-drill the holes. You will need some acetone for cleanup if you are particular about that.