Aloha when I got the 1965 Falcon station wagon, it had a medium size dent in the passenger side door. I tried pulling it out... no good... then tried drilling some holes to relieve the tension... no good... so used filler to smooth things out. I'm not happy with the outcome and was wondering how much trouble is it to replace the whole door with one without a dent or bondo ? Can two people handle the job... any special tools... etc. Thanks for any advice.
2 people can change a door easily. The tricky part is to get it aligned but if you take your time and don't rush, not difficult. The only tool you should need is a good socket and ratchet handle. Don't forget to change the lock cylinder over, and that is usually help in place by a sliding clip. On the side of the door, in line with the lock, there is normally a tab with one or two screws in it. Pull the screws and the clamp should slide out, and release the lock cylinder.
I was wondering about the hinge itself ? I don't see how you can get any tool in there to get the pin out and back in... and how about the door spring... I put one of the door springs in already and it was tricky... removing it will be likewise ? Just saw a door listed for $125, might be worth it, uh ?
As to the hinges, don't try to pull the pin between the hinge halves. Unbolt the entire hinge assembly (both halves) from the pillar post. Leave the hinge attached to the door. Most used doors come with the hinge attached. If your replacement door doesn't have the hinges, simply transfer your old one over.
When I've had to change doors on a Thunderbird (HEAVY doors, those) I leave the hinges on the post and undo the bolts holding the hinge to the door. It is much easier to get in and realign the mounting plate on the door than on the pillar if it happens to slip with no bolts holding it in place. Normally, a 3/8 inch drive ratchet handle and socket fit in there.
I don't know if the door off a two-door will fit your wagon. That said, if the door you found will fit, is an OEM piece in good shape, and won't cost an arm and a leg to ship, $125 seems reasonable. If you don't need to drill out holes for the trim, that's an added bonus. I would also keep the old door, as it would be a good hammer-and-dolly practice piece. Your Falcon wagon looks good, too. I love Falcons, mainly because my first car was a Falcon.
About those hinges: As far as I know, Ford hinges are not meant to be serviced. They are not like the G.M. hinges, where driving the pin out and putting new brass bushings in is almost routine. Fortunately, the Ford hinges do seem to stand up very well, especially on the 4 door vehicles.
