Expert: William Forster - 5/30/2007

Question
My girlfriends 2001 Hyundai Tiburon Coupe had the front edge area of the driver door crushed in and looks like a bowl. The door cannot be opened, but the windows and locking function. Over 85% of the door is untouched by the hit. I am getting conflicting stories as to whether the whole door needs to be replaced or just the outside panel. Some shops have said there is a driver protection column or pillar on that door and repairing it requires replacing out the whole door to ensure future safety. Is this true?

Answer
Door intrusion beams are made of high strength steel or sometimes Ultra Hss, and are never to be repaired or replaced. That is straight from the manufacturers, and straight from I-CAR. If bent, you can't pull it out without damaging the hinges and door striker. A door is a non-welded on part, and that is a consideration when deciding repair/replace issues. A severely damaged door can be replaced with a new shell in about 5-7 hours, a used door put on in about 2.5-3.5 hours. This door is probably junk, going by what you describe. It's not even a candidate for a door skin. Have it thrown away, and a complete shell put on.