Thanks for the replies. I am not familiar with a door edge folding tool. I can borrow a bead roller, but didn't think I would be able to fit a roller in the 1 1/2" gap between the lip and inner panel. I will go by and take another look at the bead roller. I thought I would plug weld the new outer panel to the inner panel along each side to give the lip more strength before folding the edge over. I had considered using a small cutoff wheel to score the outer panel at the fold edge to make the lip fold over easier. Would this be a good idea? Any suggestions will be appreciated. Thanks again