Fj40 door patches (1 Viewer)

[brian]

@RWBeringer4x4
Thought I start something new vs crapping all over the work thread.
And might even copy and paste in the 40 section when I'm further along.
So it's looking ccot pieces for both the inner and outer skins.
This is where I'm starting.
That measurement..which we are going to call 33.625" is the outside dia of the inner panel.

 

[brian]

The ccot is pretty close.
The rs, not so much.

The ccot is not without issues either.
Pretty sure they were aiming to have that upper "flange" actually be part of the skin.
The panel isn't deep enough, so it looks like it's going to be a flange inside the door.
Not to mention the contour isnt spot on.
Where it's at along with a gasket getting over top of it earns it a bit of a hall pass.

 

[brian]

There's a solution for this....I just dont know what it is at the moment.
I need to get rid of 10mm....and put it somewhere else

 

[RWBeringer4x4]

Awesome thanks for posting these, definitely following along.

My (completely limited) bodywork experience revolves around an old Chevy Van I've helped my father in law with a bit so any thoughts I have are from a position of complete ignorance -

I definitely see what you mean about the one crease being off. I wonder if some clever sand-bag placement and a pointed dolly would allow you to punch that crease out, using the existing line as a template. Might be able to get it to "blend" at the mating point?

Looking forward to what you come up with for a solution in order to get these lined up.

 

[brian]

Oooo let me assure you, I'm no auto body guy either...all previous success has been nothing more than clean living and good fortune.

 

[Stumpalama]

I had to chop up my CCOT floorboards back in the day to make the beads in the panels line up with the factory lines. Also, the angle of the lines was poor. I just had to cut and hammer them into shape.

 

[RWBeringer4x4]

My father in law has body-worked several old Mopars, and i picked up some rocker patch panels for his 51 Mercury as a birthday gift - I actually offered to return the Mercury panels when he first fit them fit up. I’ve never seen a patch that fits “right” so far - some just require more work than others.

 

[brian]

So doing some closer fitting the ccot panels get a thumbs up.
Perfect? No. Due more to me than them....but the location is different to see even on a lifted cruiser...plus the weather strip will hide alot if not all of it.
The hard work will getting the outside skin closed up without noticeable defects in an area devoid of any contours.

 

[brian]

As a side note it took two harbor freight flangers to finish the job.
When they work, they work great on 16ga.

 

[RWBeringer4x4]

What did you do to correct the contours mentioned previously? The slight differences in the ridges on the door bottom between the patch and the original door? Did they fall into place once completely lined up?

Also - where were the panel flangers used? To bend over the bottom? Or to create an overlap somewhere? Why two?

 

[brian]

Creates an offset....which does a few things.
Stiffens the panel and makes it easier to weld.

 

[brian]

I didnt do any additional work to them once I got my "hole" the right size....although i did cut that extra 10mm off the bottom of the inner panel.
Took two flangers cause the first one quit working halfway through the job

 

[BROKEROB1]

Very nice work!!! Mine will be due this winter or next for sure!

As a side note it took two harbor freight flangers to finish the job.
When they work, they work great on 16ga.

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[shmukster]

That is fine sheet metal work Brian. Took some time and pain to get those patch panels as nicely aligned as the pictures show. I agree heartily that given the location of these repair pieces and the fact that they are almost invisible from the inside once the door seals are attached that they are excellent offerings from CCOT. Someone would have to be a professional ball buster to question whether the doors on my 40 have been patch repaired or not. I also believe that the people who bitch about these panels have neither the patience and/or skills to make them fit as well as the ones in Brian's pictures. I have no idea whether or not my body guy got my panels as close as Brian's but I am happy with the result for sure.

 

[brian]

Fit up!
Get qc to sign off it and weld it

 

[brian]

have them welded and started cleaning them up.
the outside is going to require some filling....i knew that it would....it's a large used to be flat panel.
i already threw some body lead at it, but it still needs a little more filler.
the inside might get a glazing, or maybe not.

 

[brian]

And that's that.

 

[Stumpalama]

Good job!