Sarmark's doors

chicago · 08-16-09, 08:51 PM

Several months ago Mark had asked me to chop his 40 doors for him, like I did Rusty's. However, I was having some execution issues until recently.
Im now WELL IN TO this project and as always, learning as I go. Found a few tricks that is making it easier, but there was a learning curve of course.

Here it is....

thumper · 08-16-09, 09:53 PM

damn, nice work there. when i come out there on my visits or when i finally decide to move out there to fernley, you are going to have to give me some welding lessons. all this work on 40s is making me miss my 76 and 78, although the leg room, or lack of leg room makes me not miss them.

jon.

SARMARK · 08-16-09, 10:30 PM

Keith, you are one talented individual. I wish I had skills like you do. You certainly thought this project through. I can't say how much I am looking forward to the doors. I almost tipped my Cruiser on it's side in June when I did the Rubicon and the thought of the soft half doors hitting the ground was not a good one.

Thanks again, Mark

krokarthecrooked · 08-16-09, 11:42 PM

Very nice Keith keep up the good work me and you might have to go into bussiness together on the 40 mods and such

Dan

chicago · 08-17-09, 06:12 AM

Thanks for the niceties gents.
The down side is that I work very slow and this crap takes a while for me to do.
Once I get the handle installed, the rest is just capping it in, and finish grinding.
For those interested...1x3 in square tube fits PERFECTLY for the cap of the upper door chop. Give a more finished look, and the shape allows for straighter and more level lines. I cut it in half with the plasma.

Keith

slvrbck · 08-24-09, 09:50 PM

I know your busy with your projects....but what's up on the doors?? We need updates brotha!!!!

chicago · 08-25-09, 06:22 AM

Fgured out how I wanted to run the handles, made a bracket, got the bolts, welded in stay nuts...will weld em in tonight.
Then the capping process starts. That actually should be pretty easy.
I told Mark I work slow!

SARMARK · 08-25-09, 01:34 PM

I appreciate you thinking this project through. I sure don't have the skills to do what you are doing.

And really no hurry Keith - the longer you take the longer I have to save up to pay for the job

slvrbck · 08-25-09, 03:47 PM

I've seen your work Keith, it is fine craftsmanship that deserves to be slow and well thought out!!!

chicago · 08-26-09, 06:19 AM

Door handle is welded in, and got the cap pieces cut to fit in the top of the door. HOWEVER, Im gonna have to do some fancy fitment work at the very TOP of the slope at the leading edge of the door. The way that the door is shaped, the nice straight caps wont work, soooo....Must consider how to make it jive. Had to excise some extra steel from there off one side at least.
Ill post pics later this eve.
Unfortunately, I have not come up with an easy way to do these doors as some other have, so...Add to the fact that Im not very bright....

K

rusty_tlc · 08-26-09, 09:31 AM

Quote:

Originally Posted by chicago

.... Had to excise some extra steel from there off one side at least.
...

K

I love it when you talk like that.

chicago · 08-26-09, 06:37 PM

Quote:

Originally Posted by rusty_tlc

I love it when you talk like that.

Shop talk!!!

chicago · 08-31-09, 01:47 PM

caps are in and the PAINFUL spot welding process has begun!
Got one little section toward the back of the door to figure out the best way to run, but the hard stuff is done. Now its just HOURS of THOUSANDS of spot welds and grinding.

Pics up later. Im working late.

K

SARMARK · 08-31-09, 07:01 PM

I feel bad that you are working so hard on the doors. But I sure am excited to see them when they are done. My wife told me don't plan on retiring next year if I keep spending money on the FJ. I was thinking about suggesting she keep working to pay for the FJ. Luckily I was only thinking about saying that.

rusty_tlc · 09-01-09, 09:50 AM

Quote:

Originally Posted by SARMARK

I feel bad that you are working so hard on the doors. But I sure am excited to see them when they are done. My wife told me don't plan on retiring next year if I keep spending money on the FJ. I was thinking about suggesting she keep working to pay for the FJ. Luckily I was only thinking about saying that.

Keeping your mouth shut was a good decision.

chicago · 09-01-09, 10:19 AM

Quote:

Originally Posted by SARMARK

I feel bad that you are working so hard on the doors. But I sure am excited to see them when they are done. My wife told me don't plan on retiring next year if I keep spending money on the FJ. I was thinking about suggesting she keep working to pay for the FJ. Luckily I was only thinking about saying that.

BWWAAAAAHAHHAHAHAHA!
Thats some FUNNY stuff there.
Dont feel bad for me. Just the understanding that I take my time is enough. I love doing this stuff, but i get a bit OCD...That is my OWN fault. Im learing as I go. Ive only done ONE of these before, and it was TOTALLY different.
BTW, its a good thing Im not charging a kings ransome.

K

chicago · 09-01-09, 07:57 PM

The BIG side is almost welded in...
Here are some pics. The two bolts you all see are where the door handle goes. Just gotta seal in the OUTSIDE of the cap, and finish up the fore and aft ends, then Ill start grinding.

Mark...BY NO MEANS do I want you to feel bad! Im just NOT a big fan of sheet metal work...Primarily because its not something that Im inherently good at. Im honored to do this for you, and grateful that you thought highly enough of my craft to allow me to do it. I just HATE welding the sheet metal. That is the only reason that I bitch.

K

locrwln1 · 09-02-09, 07:08 AM

Quote:

Originally Posted by SARMARK

I feel bad that you are working so hard on the doors. But I sure am excited to see them when they are done. My wife told me don't plan on retiring next year if I keep spending money on the FJ. I was thinking about suggesting she keep working to pay for the FJ. Luckily I was only thinking about saying that.

Quote:

Originally Posted by rusty_tlc

Keeping your mouth shut was a good decision.

Bahhh, chickens, I keep trying to convince my wife to pick up that second job. I have a standard of living that I am trying to become accustomed to.

So far, she hasn't tried very hard...

Quote:

Originally Posted by chicago

The BIG side is almost welded in...
Here are some pics. The two bolts you all see are where the door handle goes. Just gotta seal in the OUTSIDE of the cap, and finish up the fore and aft ends, then Ill start grinding.

Mark...BY NO MEANS do I want you to feel bad! Im just NOT a big fan of sheet metal work...Primarily because its not something that Im inherently good at. Im honored to do this for you, and grateful that you thought highly enough of my craft to allow me to do it. I just HATE welding the sheet metal. That is the only reason that I bitch.

K

Looking good mang. Excellent work.

Jack

spressomon · 09-03-09, 10:30 AM

Quote:

Originally Posted by chicago

The BIG side is almost welded in...
Here are some pics. The two bolts you all see are where the door handle goes. Just gotta seal in the OUTSIDE of the cap, and finish up the fore and aft ends, then Ill start grinding.

Mark...BY NO MEANS do I want you to feel bad! Im just NOT a big fan of sheet metal work...Primarily because its not something that Im inherently good at. Im honored to do this for you, and grateful that you thought highly enough of my craft to allow me to do it. I just HATE welding the sheet metal. That is the only reason that I bitch.

K

Looks good Keith!!! Hey...I have a good buddy that's thinking about cutting the top off of his 80 and integrating some type of flip-pac camper top. Since you are sooooo good at massaging sheet metal and like doing it so much I was thinking you might want to take a project like this on! This could be your big chance to change professions!

rusty_tlc · 09-03-09, 10:56 AM

Quote:

Originally Posted by spressomon

Looks good Keith!!! Hey...I have a good buddy that's thinking about cutting the top off of his 80 and integrating some type of flip-pac camper top. Since you are sooooo good at massaging sheet metal and like doing it so much I was thinking you might want to take a project like this on! This could be your big chance to change professions!

Anybody we know?

locrwln1 · 09-03-09, 01:07 PM

Quote:

Originally Posted by spressomon

Looks good Keith!!! Hey...I have a good buddy that's thinking about cutting the top off of his 80 and integrating some type of flip-pac camper top. Since you are sooooo good at massaging sheet metal and like doing it so much I was thinking you might want to take a project like this on! This could be your big chance to change professions!

Quote:

Originally Posted by rusty_tlc

Anybody we know?

hmmm. Who could it be?

I am starting to look for trial 80 to practice on. So if you know of a super cheap 80 (like a grand or less type cheap), let me know.

Jack

chicago · 09-04-09, 06:51 AM

JACK!?!?!
Jack is the MAN!
He could do a FAAAAAR BETTER job than I EVER could!

What are you doing now?
Doing a can back type thing on the 80?

K

chicago · 09-04-09, 06:52 AM

Quote:

Originally Posted by spressomon

Looks good Keith!!! Hey...I have a good buddy that's thinking about cutting the top off of his 80 and integrating some type of flip-pac camper top. Since you are sooooo good at massaging sheet metal and like doing it so much I was thinking you might want to take a project like this on! This could be your big chance to change professions!

I think Ill stick with my day job!
Its much less stressful....

K

chicago · 09-04-09, 07:10 AM

Few pics of the finish...
It was much easier than I was bracing myself for. That 1x3 cap made a HUGE difference in how the welds came out. There was more backing to weld to that way, and thus virtually no burn through. PLUS, it made for a nice rounded/ beveled finish which was what I was after.

chicago · 09-04-09, 07:13 AM

There are still those low spots where the weld bead is/ was. That is the stuff that the body work guy is gonna have to fill with some bondo to make it a really nice finished product.
You just cant work that too much with the grinder, or youll screw yourself.

Ive gotta go pack for the 45 run.

Talk to you all Sunday!

Have a fun safe weekend!

K