BODY, How to save a roadster door

[the-rodster]

OK, I'm a cheap bastard. I bought a 28 RPU for $300. Well you can imagine, it's VERY rough. Some patch panels are pretty cheap from brookeville, but doors aint one of them, Soooo, let's fix 'em with homemade patch panels.

Let's start with the passenger door (practice). No matter how rough the pictures look, it's worse.

[the-rodster]

Here's the backside.

[the-rodster]

The bottom two inches are toast.

[the-rodster]

I determined that I need to replace pretty much the entire front of the door, except the top two inches. I'll scribe a line and make the cut.

[the-rodster]

After the cutoff wheel...

[the-rodster]

And I'm gonna replace the bottom two inches of the inner door... scribe the line...

[the-rodster]

Whack it off.

[the-rodster]

Now let's sandblast it to see what we have to work with.

[the-rodster]

Let's start fabbing the bottom of the inner door. I'm using 20 gage so it will be easier to work, and with all the bends, it will be plenty strong. I marked where the bead will need to be formed for the new panel.

[the-rodster]

Mark the bead, use the cutoff piece as a template.

[the-rodster]

I borrowed a bead roller from a friend and loaded it with a set of large flange dies.

[the-rodster]

With my wife crankin' the arm, I fed the panel through slowly, and it turned out pretty nice.

[the-rodster]

Close up of flange...

[the-rodster]

I then used a brake to make the bottom bend on the panel.

[the-rodster]

Next, cut out the corners.

[the-rodster]

Now the edges need to be turned down, I grabbed a chunk of steel the desired size, loaded it in the vise, and proceded to beat the edges of the panel over it.

[the-rodster]

Hey, that's more like it!

[the-rodster]

For the long edge, I placed the panel in a vise between a couple of pieces of steel and "broke" it by hand.

[the-rodster]

This is starting to look half way decent. But the panel lacks the slight curve of the door.

[the-rodster]

High tech way of getting the proper curve in the panel.

[the-rodster]

See, it worked.

[the-rodster]

Next, tack weld it every inch or so.

[the-rodster]

Then weld it solid.

[the-rodster]

And grind the weld.

[the-rodster]

Now we can tackle the front of the door. I'm using 18 gage on the front, and started by laying a piece out on the front.

[the-rodster]

After marking the edges, I bent the bottom slightly, then bent it back (I thought that this might help bend it later, and I couldn't leave the bend in when I loaded it in the brake) Then I bent both sides at a 90 degree. I also cut out the recess for the hinge and did a test fit.

[Dirty2]

Great post !!!! Now can I send you my doors? http://www.jalopyjournal.com/ubbthreads/images/graemlins/grin.gif

[the-rodster]

Once all three side are bent, it's time to put the curves in. The panel is a compound curve, bending both vertically and horizontally, by shrinking the edges in the shrinker, the gradual curve can be established. I was surprised at how little effort needs to be applied to make the curve.

[the-rodster]

After some trial and error, and test fitting, the panel is fitting pretty well.

[the-rodster]

Since we are about to join the two halves for another 75 years, I shot the inside of both pieces with some primer.

[the-rodster]

Put the panel back together, and begin rolling the edge of the outer panel over the inner panel, just like any other door skin.

[the-rodster]

Now tack weld.

[the-rodster]

And weld solid.

[the-rodster]

A skim coat of filler on both sides...

[the-rodster]

A little sanding...

[the-rodster]

A little more...

[the-rodster]

Last step, some primer.

And the finished product!

Inside.

[the-rodster]

Outside.

[the-rodster]

Let me say, that I'm no bodyman or welder. I'm a beginner at both, but if I can do it, anybody can. I also don't want to give anybody the impression that this was accomplished in a couple of hours, it took me about eight hours for the first door. Maybe the next door wil go quicker.

Well, that's about it, hope some of you guys can use the info on one of your rides.

[zgears]

http://www.jalopyjournal.com/ubbthreads/images/graemlins/shocked.gif http://www.jalopyjournal.com/ubbthreads/images/graemlins/shocked.gif http://www.jalopyjournal.com/ubbthreads/images/graemlins/shocked.gif wow!

[QQMOON]

Im inpressed Very Good
JR

[38Chevy4door]

Wow, indeed! Definitely something to file for reference!

Steve

[Tinbender]

Very nice! Tech O matic please!

[JohnnyB327]

this thing screams tech winner and tech-o-matic!!!

[wideglide74]

I'm with the wow crowd. GREAT pics, thank you for taking the time to share...

[Kustm52]

Great work there...thanks for taking the time to put the post together and show us how you did it.

Brian

[rustymetal]

very nice job thanks for sharing

[nate]

incredible, keep us all updated with the rest of your work! thanks!

[atch]

this post should serve to prod some of our lazy/sorry asses to get out to the shop and get something done.

THANX!!!

[MIKE-3137]

Now THATS what I want to see on the new and improved HAMB !!!

[CTFuzz]

i'm not gonna let this post fade away..............I have doors in that same condition sitting in my garage and I just didn't know where to start, now I do...thanks!!

[Rusty]

Very nice work. Definately a must to save for a rainy day. Great job

[haring]

Great job, and great post!

[Rand Man]

You did a great job with the metalwork and the post. I hate to say it but door skins are available lots of places. http://www.snydersantiqueauto.com/modelaparts/Doors is one example. I respect your ingenuity. You saved some cash and have the honor of saying "I did it myself".

[the-rodster]

I have a Snyder's catalog, a MAC's catalog, a Brookeville, etc. there's only a couple bucks difference between all of them

Don't get me wrong, I WILL be buying a few panels.

Complete cowl panels - $79 a pair - well worth it
Cowl post patch - $34 - yep

Door skins - $135 EACH - ouch

You just have to decide how many patch panels that you want to buy for a $300 body http://www.jalopyjournal.com/ubbthreads/images/graemlins/smile.gif

[Morrisman]

Guys like you have taken 'the fear' out of bodywork for me!

I always thought sheet metal working was some ancient black art that only gods and their offspring could do, but I now realise that sheet metal is just a chunk of steel that can be beaten and controlled, stretched and shrunk, knocked into shape without expensive tooling and that it is NOT taboo to have a few rough bits, a layer of filler, kinks, bumps and second attempts http://www.jalopyjournal.com/ubbthreads/images/graemlins/grin.gif

[born2late]

Damn, I bought Brookville doors, now I'm thinking I could have saved the old ones. Thanks for the tech!!!

[Southfork]

Very useful Tech. Hey, Thanks!

[the-rodster]

Thanks for all of the positive comments, guys. It motivates me to start on the other door, and then the cowl, and then the quarter, and then the back panel, and then ...... http://www.jalopyjournal.com/ubbthreads/images/graemlins/blush.gif

[briggs&strattonChev]

thats pretty neat, how long did it take with the shrinking machine to get the right shape?

Thanks

[the-rodster]

That part only took about 5 minutes, shrink it, test fit, shrink some more...

[rich^vic]

Very Cool.. I need to do something like this to my ride.

So when do I post the Tech on shop safety? http://www.jalopyjournal.com/ubbthreads/images/graemlins/smile.gif lose the jesus boots.. your feet will thank you when that body hammer slips out of your hand http://www.jalopyjournal.com/ubbthreads/images/graemlins/smile.gif

-Richard

[ QUOTE ]
Mark the bead, use the cutoff piece as a template.

[/ QUOTE ]

[zman]

[ QUOTE ]

So when do I post the Tech on shop safety? http://www.jalopyjournal.com/ubbthreads/images/graemlins/smile.gif lose the jesus boots.. your feet will thank you when that body hammer slips out of your hand http://www.jalopyjournal.com/ubbthreads/images/graemlins/smile.gif
-Richard


[/ QUOTE ]

Hmmmm.. Jesus boots, that's good, I always call the "birth control" shoes. Cause you'll never get laid with those ugly things on your feet, even told a girl I dated that once. She didn't think it was funny... I guess I'm just misunderstood...

[the-rodster]

Jesus Boots, hmmm, ya know, now that I think about it, my wife doesn't like 'em either. http://www.jalopyjournal.com/ubbthreads/images/graemlins/tongue.gif

[PAPASMURF]

Yeah welding with sandals is comfortable but it hurts like a mofo when the hot metal slides in between your foot and the sandal and you cant get it off quick enough while its burning your flesh. http://www.jalopyjournal.com/ubbthreads/images/graemlins/ooo.gif

I will not be wearing sandals when welding anymore, I learned the hard way. http://www.jalopyjournal.com/ubbthreads/images/graemlins/frown.gif

Awesome post bro, definite tech o matic submission. http://www.jalopyjournal.com/ubbthreads/images/graemlins/grin.gif

[Broman]

If they were good enough for Jesus.....


Great tech post BTW - you make it look like a monkey could build a door. That's the sign of a good explaination. Thnx.

[MIKE-3137]

very slick, too bad my door is trashed at the reveal on top

[bufordtjustice]

Awesome post man, I didn't even hear of it till Ryan's post about the candidates....you are definitely the winner in my book!

[Levis Classic]

Heres your tech week winner!

[Paul]

bttt