Abstract: A process for forming elongated vehicle doors includes the steps of removing the sheet metal skin from the existing door, severing the door substructure into two portions and inserting appropriately sized extension sections into the door substructure. A new elongated skin is contoured to match the side of the vehicle body and is cut to the shape of the elongated door. The new skin is placed in an adjustable mold fixture and end flange portions are hammered over the mold. The adjustable mold includes two lower portions which are contoured and configured to simulate the underlying door substructure, and two upper mold portions similarly contoured and configured, which are clamped to the lower mold portions with the new skin between the upper and lower mold portions. The molds are kirksite molds made directly from components of the door, and adjusting the spacing between the mold portions permits the manufacture of skins of different lengths to go on doors of different lengths.