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Certainly a possibility, perhaps it could be prevented by welding some small section angle bits across the inside of the skin. Welded to the frame at each end, and some stitch welds to the skin along the lengths. Most modern cars are fully hot-dip galvanised, and some of the bodywork panels are very thin on those! I'm sure the curvature of modern panels helps, but there must be a way around it. I mean, imagine having galvanised doors :ph34r:

Of course you could just galvanise the frame and wrap an aluminium skin around it and avoid the problem altogether :P

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Certainly a possibility, perhaps it could be prevented by welding some small section angle bits across the inside of the skin. Welded to the frame at each end, and some stitch welds to the skin along the lengths. Most modern cars are fully hot-dip galvanised, and some of the bodywork panels are very thin on those! I'm sure the curvature of modern panels helps, but there must be a way around it. I mean, imagine having galvanised doors :ph34r:

Of course you could just galvanise the frame and wrap an aluminium skin around it and avoid the problem altogether :P

looking at the pics of the door it looks like its lightly galvanised anyway but im not sure

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Most modern cars are fully hot-dip galvanised, and some of the bodywork panels are very thin on those!

I don't think this is correct. Most modern cars are made from steel which is zinc coated, but the galvanising is put on the steel strip by the steel mill, not after the steel has been pressed and assembled.

I've spent quite a lot of time in car body press shops of various manufacturers and I can confirm that they use an astonishing variety of different thickness, composition and surface finish.

Nick.

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