Rusty's doors - Page 2

chicago · 03-18-09, 07:48 PM

Okay...
So the DS door wasnt as straight nor clean as the PS door. There was this NAST RUSTED ASS section on the bottom of the door where it meets the sill. How the F*CK am I gonna do this. Rusty Dan and I comiserated on the subject, and he gave me the go ahead.
I will say...This is REALLY FAWKING HARD to do, try to recreate the factory bends with FLAT 18 ga sheet metal. NOT FUN!
Well see how it turns out. Here is the task thus far.

K

chicago · 03-18-09, 07:51 PM

Here are some more!
This is the only way that I could think to make that bend at the lower corner. This is the spot that concerns me the most.

Wish me luck!

DesertLake · 03-18-09, 07:59 PM

What are you using to make the bend?

DiscoveryXD · 03-18-09, 08:00 PM

could you cut a flat piece out that coppies that width and radius and put the curve in it?

kinda hard to explain what I mean... looks tricky for sure, but the challenging ones are what you learn and get better with!

chicago · 03-18-09, 08:05 PM

Quote:

Originally Posted by DesertLake

What are you using to make the bend?

Sheet metal break.

chicago · 03-18-09, 08:09 PM

Quote:

Originally Posted by DiscoveryXD

could you cut a flat piece out that coppies that width and radius and put the curve in it?

kinda hard to explain what I mean... looks tricky for sure, but the challenging ones are what you learn and get better with!

NOPE.
I used a flat piece that was bent with the angles in the original, and the most effective way to do it, was cut a bunch of slits in it, and make the bend around the lower edge of the door.
I tried cutting radius's and doing each angle individually, its just too frickin hard. The material is thick enough, and with all the filler that will be going in, I should be able to shape it pretty well with the angle grinder and a flap disc sander.
I could have take the easy route and just angled it in flat...
But what fun would that have been?

DesertLake · 03-18-09, 08:15 PM

I didn't realize you could make "gentle" curves with those.
N00b.

rusty_tlc · 03-18-09, 08:16 PM

You have gone way beyond the call of duty on this project.

chicago · 03-18-09, 08:24 PM

Quote:

Originally Posted by DesertLake

I didn't realize you could make "gentle" curves with those.
N00b.

Well...yes and no...
It did take some "massaging" to get the slopes to match.
I picked up the HF 30 in brake...Its a POS, but it did DO the bends, so I cant say too much bad about it.
I wont be using it too much, so its good enough for that purpose.
I WOULD NOT suggest it for the 18 ga material. 16 I think it would work pretty well, but anything more....you're struggling.
Ive spent HOURS on this stupid rust section, but...LEARNING is taking place if nothing else.

K

chicago · 03-18-09, 08:25 PM

Quote:

Originally Posted by rusty_tlc

You have gone way beyond the call of duty on this project.

Im confident that it WILL ultimately turn out nice for you. Looks like crap now, but when I can do some of the finish grinding, it will look much better.

K

chicago · 03-18-09, 08:27 PM

I think the straight run came out pretty good...

chicago · 03-24-09, 07:36 PM

More progress!

chicago · 03-24-09, 07:37 PM

One more!

DiscoveryXD · 03-24-09, 08:14 PM

Nice Job Keith! lookin good!

chicago · 03-24-09, 08:28 PM

Quote:

Originally Posted by DiscoveryXD

Nice Job Keith! lookin good!

Thanks...
Gonna need some bondo to fill the low spots, but...that's what's gotta happen.
It'll be better than the rust anyway.

slvrbck · 03-24-09, 08:36 PM

You do some good work bud!!!

chicago · 03-24-09, 08:55 PM

Quote:

Originally Posted by slvrbck

You do some good work bud!!!

I appreciate it!
I really HATE sheet metal work though.
The chop was straight forward, but this lower edge rust that Im fixing...NOT my favorite.

My OCD is really coming to light with this.

K

DesertLake · 03-24-09, 09:22 PM

What did you fill the slits with? Assuming molten metal, what type of welder?

24HOURSOFNEVADA · 03-25-09, 12:09 AM

Nice job K-

You should be really proud of how that turned out.

chicago · 03-25-09, 06:29 AM

Quote:

Originally Posted by DesertLake

What did you fill the slits with? Assuming molten metal, what type of welder?

Yeup!
Actually, some of the wider "slits" I cut pieces to fill in the gaps, other wiset was a lot of fill welding. Fill welding is stressful and tedious.
My welder is a Hobart 187 mig. I use flux core, not gas.

Turn the setting all the way down for this ga material and run the wire speed at 30. You wanna get the metal down as quickly as possible before it burns through. Its literally a ZAP, then stop.
Did I mention that sheet metal is a PITA!

K

chicago · 03-25-09, 06:31 AM

Quote:

Originally Posted by 24HOURSOFNEVADA

Nice job K-

You should be really proud of how that turned out.

thanks man!
BTW, Mike R and I had a discussion about you over a beer one Sunday.

OKAY...it wasnt ALL entirely about you, but you did come up in conversation.

K

locrwln1 · 03-25-09, 07:23 AM

The doors are looking great. Is there going to be anyway for water to get into them? I know that you are capping the top, but are there going to be some kind of "pocket" type things on the inside? If so, you might want to figure out one or two little drains at the bottoms. I'm not sure how the factory did it, just something to think about. I would hate to see you do all of that work and have them rust out prematurely.

I'll shut up now.

Jack

chicago · 03-25-09, 07:18 PM

Quote:

Originally Posted by locrwln1

The doors are looking great. Is there going to be anyway for water to get into them? I know that you are capping the top, but are there going to be some kind of "pocket" type things on the inside? If so, you might want to figure out one or two little drains at the bottoms. I'm not sure how the factory did it, just something to think about. I would hate to see you do all of that work and have them rust out prematurely.

I'll shut up now.

Jack

From the factory, they had some seemingly NON EFFECTIVE slits at the bottom that apparently got plugged up over the years and caused water to sit and then rust.
Ill do what ever Rusty Dan wants me to do with them.
As it is, he was talking about putting a new covering on the inside of the door, and Im not 100% sure that will keep all the H2O out, but...It will certainly be much more difficult for it to get IN.

K

DesertLake · 03-25-09, 08:24 PM

Just get a bunch of dessicant packets and throw them in there.

again

rusty_tlc · 03-25-09, 09:01 PM

I think I'll be almost ashamed to put those on my POS. they will defiantly be the nicest part of the body. I guess we will have to drill some weep holes along the bottom to drain any water out.

chicago · 03-25-09, 09:12 PM

Quote:

Originally Posted by rusty_tlc

I think I'll be almost ashamed to put those on my POS. they will defiantly be the nicest part of the body. I guess we will have to drill some weep holes along the bottom to drain any water out.

Might not be a bad idea.
However, it wont be as bad with the top capped. It seems like there'd be a lot of water shed with the windows in place, and thus...trapped water. But still...we were planning on leaving some pockets in the door for your speakers and a lil glove cubby. Water might find its way in there.

locrwln1 · 03-26-09, 07:35 AM

Quote:

Originally Posted by chicago

Might not be a bad idea.
However, it wont be as bad with the top capped. It seems like there'd be a lot of water shed with the windows in place, and thus...trapped water. But still...we were planning on leaving some pockets in the door for your speakers and a lil glove cubby. Water might find its way in there.

Especially when the top won't put its self on.

Jack

rusty_tlc · 03-26-09, 09:37 AM

Quote:

Originally Posted by locrwln1

Especially when the top won't put its self on.

Jack

Let a guy get caught off guard by an early season snow storm and he hears about it forever. You guys are as bad as my wife, she still brings up stupid shit I did 30 years ago.

spressomon · 03-30-09, 07:57 AM

Nice job Keith! Do you have oxy/acy? You could use brass to fill in the low spots on the bottom of the door(s) if you do. I imagine if you had a gas welder you'd already have thought of that

chicago · 03-30-09, 07:37 PM

Quote:

Originally Posted by spressomon

Nice job Keith! Do you have oxy/acy? You could use brass to fill in the low spots on the bottom of the door(s) if you do. I imagine if you had a gas welder you'd already have thought of that

Thanks Spresso!
I already took the liberty of essentially RE DOING the corner.
I didnt go so far as to cut it out and start over, but I re welded the whole section over and used the weld to build up the low spots.
Im feeling better about it.
Regardless, that is a rather good idea brazing the low spots in...
I actually hadnt thought of it.
There is gonna be bondo, but at least I wont have to use it to build up the shape that I was trying to achieve. As it was before...well, it just looked SHOTTIE.

K