Projects winter project - "so let's chop a 40 coupe (and fab everything else possible...)

Very interesting & innovative solution to the hinge problem!



Now what to do.
The next step is the inner frame of the door,
so the hinges have a place to go.
Than the hinges,
than the bottom of the door jamb,
than the bottom of the door,
than attaching what's left of the original door....

Holy chit.


Then do it all over on the pass side !! Keep it up !

 

Travis, As usual you are coming up with a simple completely home-made hinge system. I just knew you would.


Dave

 

dude, this thing is wild... I love it. Can't wait to see these hinges in action...

 

...And you think I'm crazy!

Looking great Travis! I love this thread, because you've got so many ideas on how to attack a problem.

 

Gee thanks Koolkemp for putting that in better perspective!

Me too, I'm hoping they will work!

Thanks Buddy -
I've got a shop full of things to put (a couple) cars together,
so usually the ideas are forced from the pieces I've got!

Chaddilac and 41dave - thanks for keeping tabs on the progress!

TP

 

Looking good Travis!

 

This build rocks! Love your work Zibo

 

This is awesome! Lookin forward to more updates


-LUKEY-

 

I'm changing your nick name from "CHAVES" to the "Wiz Wizzard" cause your amaizing.

 

This is awsome!!!!!...... I enjoy checking in on your progress and I have to say it is what I thought it would be .............BAD ASS!!!!!!!

 

Thanks guys for the interest!

Here you go Grimlock...

Last time I left ya guys,
the heim joints were bolted in place.
My plan of attack wasn't too coordinated yet.
I figured making the door part of the door jamb would be good.



Nah.

That wasn't the place to start.
It was a needed piece of the puzzle though not right now.



This has all been over the course of 3 weeks now.
2 hours or so every couple nights after work.
My subconscious brain was hammering out ideas in the meantime.

Since the door jamb has a light curve,
but the hinges work on the same pivot line,
each hinge position is a little different - top, middle, bottom.
So cardboard templates were made up,
than whittled out of some 1/2" steel,
with this high-powered cutting tool.


Ok just kidding.
It is a great for scribing the torch line though.
Pen, pencil and chalk disappear,
but that fine cut line is easy to see through the flame.



I did a matching pair each night.



the bottom were the trickiest.



bolted up with some clamps,
it seemed like they'd work.


closed


open

the top 2 holes in the jamb had plenty of clearance,
but the bottom hole could be opened up for even more open angle.

At this point I was undecided about
- threaded hinges vs threaded doors.
I'd go to sleep thinking which way was best.


I figured bolting the door to the hinges was easiest,
than the door could be a flat piece instead of a bunch of welded pieces.
The only issue was the door would be slotted to insert the hinges.



So keeping with the SS nutsert theme,
little flags were made for each hinge.


Than a temporary strap was tacked on to position the hinges.
This also helped in opening up the holes where needed.


Yesterday I had a lucky day at the shop.
With the hinges adjusted,
the new door part was cut and drilled
The holes were one step drill oversized which was the adjustment needed.


The door jamb part was waiting to be trimmed and welded.


This really stiffened it up.
It was a relief that there was no friction in the moving parts.


Than some angle stiffeners were welded up.
Now the door frame was really rigid.




I still need to open up the bottom hole,
which can be notched out at least 1/4" more,
so there should be plenty of opening.

So now I'm at the stage where the rusty door can be grafted to the new hinge box.
It has seemed like trudging uphill this past couple weeks,
everything was moving in slow motion.
Even though there's a ton of work left,
it seems so close,
I really want to see a working rusty door!

TP

 

Wow!!!!!!

 

Awesome fab work!

 

Wiley Coyote. Suuuuuuper Genius.

 

Thanks guys for the comments!

*****

So yesterday I had to do the doors.
They were sitting there and I couldn't resist.
I had another shop project but it could wait.



I had already finished welding up those door hinge boxes.



And thankfully they didn't warp out.

I started on the passenger door,
so if I screwed it up I wouldn't have to see it.



I had made the bottom frame and brace last year,
but ended up cutting it all out.
It was good to set up the temporary hinges with at least.

Not much was left of the door frame after the graft line was cut.
But it was what I needed to graft the old with the new.



My trick was tacking the door onto the body,
than welding the hinge to the door.
The gaps were really tight around the sheetmetal,
so while it was tacked up,
I sliced a gap and zapped it a couple times to hold it back to the door.
The door frame itself was also a little tight on the back part,
so the frame was sectioned a tiny bit and rewelded too.



It was exciting to pop those tacks,
and watch the door swing open.



The door barely sagged if at all,
and the hinges were really solid feeling.
They were actually smoother with the weight of the door.

All this took under 4 hours,
as there was alot of thinking involved and double cuts.
I had kid duty in 2 hours,
but thrashed to get as much done as possible on the driver door.



I had forgot to mention but another strip was needed to support the front doorskin.
It was the same flatbar used to support the hinges,
and was the perfect size needed.
It's tough to see,
but its there where the front seal would be.
Fortunately I had done both sides earlier that day.



it was alot faster the second time around.
This door fit much better.
The sheetmetal gaps were still tight in the back,
but at least the frame itself wasn't too wedged like the other side.

This doorskin was a little more beat up on the front part,
but it was straight enough so it was flush with the body lines.



Since each part - cowl, door, body - has had so much work,
independent of the other pieces,
it was lucky that the reveal lines matched up decently.



This took all the 2 hours I had to spare.
So as soon as I cut the tacks off and tested the hinge,
I had to leave.



It's been a long time,
well, never since the door worked with real hinges.

In a way I jumped the gun,
as I should have made the bottom door jamb part first,
than made the door bottom to match the body,
but seeing a complete body (less the bottom patch)
is well worth it!

TP

 

I'm amazed. I can't believe you've turned rust into this!

 

Bravo sir.

I am looking at your work and am amazed. Thank you for posting

 

have you seen bumpstick's "buried treasure in hollywood" thread? you've already fabbed almost everything, but that car may have some metal you could salvage.

 

You have serious talent, love the hinges and door jambs!

 

Been watching this thread for a long time,you do amazing work.Wanna come over and fix some of my POS rustbuckets?

 

Travis, there is no doubt that you rule!

 

Thanks guys for all the positive comments!
It hurts not too be able to work on it for the past week or so,
i've got another guys project and my $$ job taking most of my time.

Yeah Ray,
I remember his post from a year or so ago.
That cowl section would have been a perfect replacement,
but I had just finished replacing the cowl top.
Plus what's the fun in just cutting and pasting you know!

Williebill,
If you knew how much time its taken...
I'm not sure if its cost effective to fix or find a better body!
However,
I've found some good tricks along the way that I wouldn't have otherwise.

Anyway thanks again,
glad you guys are interested.
I'll get some time in over the weekend!

TP

 

Cost effective, this hobby is not cost effective! I believe that the satisfaction of turning a(p o s) that no body wanted into a great looking and driving car far exceeds the money. Just my thoughts.
This forty is looking great and is keeping me on track to have mine running next summer.
Thanks for the motavation George

 

X2!!!! just wow!!!!

 

Travis, Have been watching this for some time and just had to get my two cents in on this outstanding job of saving something that most of us would have just used for parts. I know all of us that follows this thred wish we had just a little bit of the skills you have . Way to go dude......Keep the updates comming can't wait to see this car done.

 

Awesome build and great fabrication skills! Well done.

 

Hey Zibo. Mike here in S.E. Kansas. Don't really know where to start to express my admiration for the work you have done on your coupe so far. I stumbled on the thread yesterday and read till my eyes wore out and just now took the time to finish it. Over the top? Sure! Cost effective? Hell no! Precision application of artistic ability and craftsmanship is without a doubt an understatement. You deserve every compliment that has been sent your way and more. I have honestly had it with the current "entitlement mindset so many folks subscribe to. Makes me proud to know there are still young guys out there that have the can do mentality and the ambition to stick with a project and see it through. Makes me feel pretty good about my old 36 Master Chevys condition looking at what you had to start with. I just signed on to the Hamb a few weeks ago. Been lurking for a while and you sir are the epitomey of the "traditional hot rodder". I will be lurking and waiting for all your updates. Nuff said, Mike.

 

Cant believe I missed an update! Pure genius on the hinges I love your work. Besides fixing rusty junk we have some thing else in common...I start with the pass side for the same reason you do lol ! Keep up the great work Zibo!

 

Travis, Excellent progress. The hinges are simple and stylish. They really work out for you. Now all you got to do is finish the door repairs. Will be checking in for further updates.

Dave