Welcome to the THE H.A.M.B. forums.

You are currently viewing our boards as a guest which gives you limited access to view most discussions and access our other features. By joining our free community you will have access to post topics, communicate privately with other members (PM), respond to polls, upload content and access many other special features. Registration is fast, simple and absolutely free so please, join our community today!

Go Back   THE H.A.M.B. > General Discussion > The Hokey Ass Message Board

Reply
 
Thread Tools Display Modes
Old 03-12-2011, 10:00 AM   #1
rottenleonard
Alliance Member
 
rottenleonard's Avatar
 
Join Date: Nov 2008
Location: Lewiston Idaho
Posts: 1,149
Default Tech week; Rottenleonard's scratch built doors

Wa hoo I love tech week..... Thanks Baileigh!!!!

I think there are some people that could use this, Whether they have an oddball body that is hard to find door for or a model a that re pops are made for but will set you back a stack of cash( I'll have less than 100 dollars into both doors and what you will see took me one day)

Now what I'm working with is a 28-9 roadster back section and a pickup cowl(hey who's hissing?) I want to make one body to take to the Portland swap meet next month to sell with the proceeds going to my model a 5 window body fund. The roadster body had been hacked up pretty severely but I think I can make something someone could make a cool rod out of cheap!

Here we go; Start by figuring out how thick the jam blanks need to be, Mine is going to have three inches on the inside of the door, three in the jam and 3/4" setback from the door edge.



next take and cut a blank and bent 90 degrees to form the inside corner of the door



take that blank and clamp it to the door jam




and then trace the door opening on to it




next used dividers to make a line for the set back(mine is 3/4")




and cut that line






now off to the bead roller with a set of tipping dies, If you don't have a bead roller you could use flanging pliers.




roll the body line in several steps




notice how wavy this makes the flange



plannish out the waves (sort of like tuck shrinking)





Now you will find that the flange caused the piece to bow




Here you will need to shrink the flange, you could use relief cuts or tuck shrinking but I'm going to use my shrinker. ( notice where it's made, probably the best piece of info on this thread is if you are thinking of buying one like this save you money for a baileigh, as this one is not worth the poorly refined scrap iron it's made out of)



now that my rant is done back to shrinking the flange, just go a little at a time and check with a straight edge



here is the piece refitted to the jam







to be continued( i had gotten almost this far and hit the wrong button and lost it...I love computers)
offline   Reply With Quote
Old 03-12-2011, 10:24 AM   #2
rottenleonard
Alliance Member
 
rottenleonard's Avatar
 
Join Date: Nov 2008
Location: Lewiston Idaho
Posts: 1,149
Default Re: Tech week; Rottenleonard's scratch built doors

Next we just rinse and repeat for the rear jam













Next was to make the bottom of the door, it starts out in the same fashion but the setback will be 1 1/2" to allow for a splash guard under the door. you can see where it goes on the cowl.



just measure the same way. because of this mismatched bastard child my door is tapered on the bottom, this is o.k. but needs to be accounted for. If you aren't doing something weird like me these measurement will probably be the same.



To save time I bought a door skin for a model a pickup, they are dirt cheap and I don't have a English wheel to make skins.
I have used a method to make skins that I got off the professor hammer article in classic trucks for making a compound curve in flat sheet metal, here are some picts from my Chrysler build

you make a grid on your sheet and planish with a hammer and dolly at each intersection, this stretches the metal and makes the compound curve, It worked well, and is very controllable, but requires time and a skim coat of filler to remove the hammer marks






Anyways back to our current victim, Right or wrong I used the bottom of the door skin to find the curve of the bottom of the door. keeping in mind the offset measurement take previously




then followed the procedure from the sides






offline   Reply With Quote
Old 03-12-2011, 10:55 AM   #3
rottenleonard
Alliance Member
 
rottenleonard's Avatar
 
Join Date: Nov 2008
Location: Lewiston Idaho
Posts: 1,149
Default Re: Tech week; Rottenleonard's scratch built doors

Now I needed to fold over the flanges on the skin and that is pretty straight forward.

just tap it down over a dolly



in a few steps




leaving just enough space to slip in the door frame




now it is time to start fitting the frame

with the bottom installed and the side layed over the top you can start to figure out how to trim the pieces to make this work,







the bottom piece gets trimmed first for the 3/4" setback of the front and rear pieces.





this allows you start fitting the side, lay it over the bottom and trace to make your cut line



here it is trimmed on the end and overlapped with the bottom




next cut one at 45 degrees, then reinstall and trace the other to make a tight joint




cut the other




starting to look like something

repeat on the other end









clamp it all together




and reward yourself with some teasers






next it's back to the bench for welding, use a lot of small tacks to keep warping down and grind flat.








offline   Reply With Quote
Sponsored Links (Register now to hide all advertisements)
Old 03-12-2011, 11:21 AM   #4
rottenleonard
Alliance Member
 
rottenleonard's Avatar
 
Join Date: Nov 2008
Location: Lewiston Idaho
Posts: 1,149
Default Re: Tech week; Rottenleonard's scratch built doors

Now for the body line



I started out by cutting a blank and bending about 70 degrees




Then 3/8" from there bent an opposing angel, then measured the width of the style line and bent 90 degrees to form the top of the door.








I put that aside and formed a 90 degree angle piece to make the inside top portion of the door.




then cut and trimmed just like the sides and bottom




next stand the door up upside down, lay a sharpie flat against the door skin and trace a line



the sharpie makes it's mark 1/4" from where you need it




so now you need to use the dividers to make a cut line that is 1/4" plus the width of the style line upper flange away from the line you just traced, and then cut.



now use whatever shrinking method to shrink the flange on the style line piece to match the door structure, You will need to use your English knee a little to adjust it.






next fit the piece as needed, panel clamps rock!



and tack it into place






trial fit........... Don't you hate it when the reality of something doesn't work the way you had it drawn in your head.




I'm not sure what I was thinking but I guess that happens, out comes the cut off wheel for a redo.

This time I used a 3/16 step die on the bead roller and that made the style line a lot more appropriate, then refitted the new piece in the same manner as the incorrect one, I also had to trim back the top inner structure

re fitting much better



tacking in


Last edited by rottenleonard; 03-12-2011 at 11:49 AM.
offline   Reply With Quote
Old 03-12-2011, 11:39 AM   #5
rottenleonard
Alliance Member
 
rottenleonard's Avatar
 
Join Date: Nov 2008
Location: Lewiston Idaho
Posts: 1,149
Default Re: Tech week; Rottenleonard's scratch built doors

continued




permanently attaching the inner structure



and filling the ends of the style lines with weld







Those pictures aren't blurry, you have just been drinking

back onto the car for some reward shots










I will move on to the other door and other projects as I periodically come back to this door for spot welds, I find that this helps with patience and keeping the panel cool to avoid warping.



This was all done in one day and was defiantly a (good enough for the girls we date) project, that could be slowed down and refined for better fit and finish. The more effort you put into it will be reflected in the final product. but all of the principles would be the same. I used 20 gauge for the whole door, which seems flimsy but once everything is together the door is light and VERY stiff. I will add inner supports where the hinges will be mounted to stop cracking other than that I think it will work well and looks a little more "right" than making doors from box tube.

I hope this helps someone, I'll come back and post more pictures here as the body progresses Thanks Rottenleonard
offline   Reply With Quote
Old 03-12-2011, 11:47 AM   #6
Hot Rod Ron
Old School HAMBer
 
Hot Rod Ron's Avatar
 
Join Date: Mar 2001
Location: Tucson/Phoenix AZ USA
Posts: 2,850
Default Re: Tech week; Rottenleonard's scratch built doors

Great post with nice photos.
offline   Reply With Quote
Old 03-12-2011, 11:48 AM   #7
HotRod33
Senior Member
 
HotRod33's Avatar
 
Join Date: Oct 2008
Location: Arnold MO
Posts: 2,234
Default Re: Tech week; Rottenleonard's scratch built doors

You made it look pretty easy...... nice tech article...... I'd vote for you just send me the doors........
__________________
Autism and the Garage social Group..... HAMB Chapel
offline   Reply With Quote
Old 03-12-2011, 11:53 AM   #8
Max Gearhead
Alliance Member
 
Max Gearhead's Avatar
 
Join Date: Oct 2002
Location: Frustration Station, WI.
Posts: 2,456
Cool Re: Tech week; Rottenleonard's scratch built doors

Wow, that's amazing work.
__________________
Posted telepathically from my mancave


Join the 348-409 Chevy group.

http://www.jalopyjournal.com/forum/g...hp?groupid=125

Primates CC
offline   Reply With Quote
Old 03-12-2011, 11:59 AM   #9
chrisntx
Senior Member
 
Join Date: Jan 2006
Location: Texas .
Posts: 1,765
Default Re: Tech week; Rottenleonard's scratch built doors

thank you Leonard!
this kind of post is the biggest reason I come to the HAMB
offline   Reply With Quote
Old 03-12-2011, 04:09 PM   #10
rottenleonard
Alliance Member
 
rottenleonard's Avatar
 
Join Date: Nov 2008
Location: Lewiston Idaho
Posts: 1,149
Default Re: Tech week; Rottenleonard's scratch built doors

Quote:
Originally Posted by HotRod33 View Post
You made it look pretty easy...... nice tech article...... I'd vote for you just send me the doors........
Hell let's make a deal and i'll send the whole car
offline   Reply With Quote
Old 03-12-2011, 06:06 PM   #11
bct
Senior Member
 
bct's Avatar
 
Join Date: Apr 2005
Location: b.c.
Posts: 1,369
Default Re: Tech week; Rottenleonard's scratch built doors

nice work leonard. funny thing, i'm working on my plasma tracer today.all the best. keep up the good work.
__________________
a time to weld , a time to grind.
offline   Reply With Quote
Old 03-12-2011, 07:31 PM   #12
rottenleonard
Alliance Member
 
rottenleonard's Avatar
 
Join Date: Nov 2008
Location: Lewiston Idaho
Posts: 1,149
Default Re: Tech week; Rottenleonard's scratch built doors

Quote:
Originally Posted by bct View Post
nice work leonard. funny thing, i'm working on my plasma tracer today.all the best. keep up the good work.
I wondered if anyone built one, post some pics.
offline   Reply With Quote
Old 03-12-2011, 07:49 PM   #13
HotRod33
Senior Member
 
HotRod33's Avatar
 
Join Date: Oct 2008
Location: Arnold MO
Posts: 2,234
Default Re: Tech week; Rottenleonard's scratch built doors

Quote:
Originally Posted by rottenleonard View Post
Hell let's make a deal and i'll send the whole car
Thats just what I need another project........... I already have more projects than I will get done before I die........ LOL
__________________
Autism and the Garage social Group..... HAMB Chapel
offline   Reply With Quote
Old 03-12-2011, 07:50 PM   #14
JeffreyJames
Old School HAMBer
 
JeffreyJames's Avatar
 
Join Date: Jun 2007
Location: SUGAR CITY
Posts: 16,571
Default Re: Tech week; Rottenleonard's scratch built doors

Nice work!!! You get my vote for tech week winner as you could put some of the metal working tool to goo use!
__________________
I PLAY WITH TIGERS
WWW.SUGARCITYSPEEDSHOP.COM
offline   Reply With Quote
Old 03-12-2011, 07:56 PM   #15
Kevinsrodshop
Member
 
Kevinsrodshop's Avatar
 
Join Date: Aug 2009
Location: Calgary Alberta
Posts: 529
Default Re: Tech week; Rottenleonard's scratch built doors

Nice work! Tech week is the best.
offline   Reply With Quote
Old 03-12-2011, 10:55 PM   #16
bct
Senior Member
 
bct's Avatar
 
Join Date: Apr 2005
Location: b.c.
Posts: 1,369
Default Re: Tech week; Rottenleonard's scratch built doors

here ya go...pics
just about there...used a salvaged awning frame for material



48? ford panhard bar ends the plaz tip fits good just have to cut them so they will pinch second one for stylus



i can't tell you how many squares i've ruined by nicking them with the plaz. i think that it will get the most use without a pattern , just useing the upper bar for straight cuts. thanks for the step by step.peace
__________________
a time to weld , a time to grind.
offline   Reply With Quote
Old 03-12-2011, 11:18 PM   #17
Ian Berky
Old School HAMBer
 
Ian Berky's Avatar
 
Join Date: Nov 2007
Location: Riverside, California
Posts: 3,674
Default Re: Tech week; Rottenleonard's scratch built doors

Great tech man!!! Super talented and creative!!!! Rules!!!
offline   Reply With Quote
Old 03-12-2011, 11:52 PM   #18
studog51
Member
 
studog51's Avatar
 
Join Date: Jul 2008
Location: lake view terrace, los angles
Posts: 919
Default Re: Tech week; Rottenleonard's scratch built doors

awesome tech piece.... very easy to follow...thanks and good luck
offline   Reply With Quote
Old 03-13-2011, 12:30 AM   #19
Atwater Mike
Old School HAMBer
 
Join Date: May 2002
Location: Atwater, CA. USA
Posts: 3,626
Default Re: Tech week; Rottenleonard's scratch built doors

Good down to earth fab...without a wheel. Good thinking. Grid idea is a good idea.
Inspiring...
__________________
Mike in Atwater
offline   Reply With Quote
Old 03-13-2011, 12:59 AM   #20
Woob
Grenade Inspector
 
Woob's Avatar
 
Join Date: May 2004
Location: Falcon, CO
Posts: 311
Default Re: Tech week; Rottenleonard's scratch built doors

Quote:
Originally Posted by chrisntx View Post
this kind of post is the biggest reason I come to the HAMB
Amen to that!

As soon as I get done with my '36:



Awesome stuff!
Thanks!
__________________
ColoradoMelons.com
offline   Reply With Quote
Reply

Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On

Forum Jump

Sponsored Links (Register now to hide all advertisements)


All times are GMT -5. The time now is 05:48 AM.