Rusty's doors

[rusty_tlc]

Did ya get the wrap bar stuff done?
I was expecting a call on that too!



K

I got some work done on it. I wanted to have you look at the part that ties to the cross member before I cut to length. I used a die grinder to prep the holes I do have cut so it took a while.

When I went to install the rear springs I didn't have lock washers and they don't have the right size at HD. I'll pick then up from R&E today. Once I have the rear axle back under the rig I'll feel a lot more comfortable working under it. Plus the jack stands will be out of the way.

 

[chicago]

Dan,
Got the door all capped in.
I was wondering if you wanted to do a test fit before I fill the upper part where the arm rest will not be?
If anything needs to be tweaked...

K

 

[slvrbck]

DAAAAANNNNGGG, looks sweet. Wanna do another set???

 

[chicago]

DAAAAANNNNGGG, looks sweet. Wanna do another set???

SURE!
Ive got extra sheet metal...Ive kinda gotten the hang of welding this stuff so its not so much..."burn through...s***....wire wheel, grind weld...etc." Youve gotta build up the bead so you can smooth it out without taking off too much material and exposing holes/ seams, then have to go back and re fill with weld. Its still a PITA, but its getting better. I still prefer some heavier steel any day.
Ive still got one more door for Rusty, depending on what he wants to do with the one that is "finished"

K

 

[slvrbck]

Cool, I'll shoot you a PM and we will sort out particulars. I might as well chop the doors, I decided that I am going to back half it, so who f'ing cares about full doors!!!!

 

[rusty_tlc]

I'd like to test fit, I just need a set of hings and pins. Maybe Dan G has some?

 

[24HOURSOFNEVADA]

Those look great.

 

[rusty_tlc]

We did a test fit today, without hinges. It looks better in person. I can't wait to give them a coat of Krylon Hunter Green and mount them up.

 

[spressomon]

Nice job Keith!

 

[chicago]

Nice job Keith!

Thanks!
Wanna do the hundy doors?

K

 

[chicago]

The challenge!!!!

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 **** 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]

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]

What are you using to make the bend?

 

[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!

 

[chicago]

What are you using to make the bend?

Sheet metal break.

 

[chicago]

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]

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

 

[rusty_tlc]

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

 

[chicago]

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]

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