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OT Semi-Tech - Building a Door

Discussion in 'The Hokey Ass Message Board' started by 52pickup, Jul 13, 2006.

  1. 52pickup
    Joined: Aug 11, 2004
    Posts: 833

    52pickup
    Member
    from Tucson, Az

    I was planning on doing a full tech piece on building this door, but I forgot to take pictures while I was doing most of the dirty work, so this is kinda just a summary. Anywho, the door is off a 54 Doretti Swallow, some might remember me showing fixing up the rear fender for this car in a post a few months back.

    The door was pretty twisted, it had been hit hard at some point in its life, and was never really fixed right.It had some half-assed brazed in patches, a bolt welded in as a structural member of the door, and a whole lot of filler and fiberglass.

    [​IMG]

    You can see some of the chunks I chipped off laying on the door in this pic.

    [​IMG]

    After I peeled the skin off, I cut out the bad frame pieces and beat out new pieces from 18ga. The whole door was done by hand, I dont even have a break to use, all the bends were made by clamping the sheet under a piece of heavy angle at the edge of a table and beating it over with a hammer.

    [​IMG]

    you can't see it here, but I made all the gaps on the door frame perfect to the fenders, though bigger than I ultimatly wanted. That way I could roll the skin around the frame,following the frame as closely as I could, and end up with good gaps.

    [​IMG]

    The only exception to the by hand comment was I took the skin to a guy and used his slip roll to put some shape the skin before I attached it to the frame. I tried to bend it over a piece of tube that was laying around, but I'm not what one would call a big guy, and that piece of steel just laughed at me.

    Here is a pic with the skin on and the door kinda in place(it wasnt aligned very well yet). Gaps needed a little tweeking in a couple places, but nothing more than a 1/16th or so.

    [​IMG]

    Over all I think it came out pretty good, especially for my first attempt at what was basically building a door from scratch. I learned a couple things that will make my next easier, and hopefully better.
     
  2. Impressive work!
     
  3. LoungeLife
    Joined: Jun 22, 2004
    Posts: 619

    LoungeLife
    Member
    from Tulsa

    Very impressive.
     
  4. hammeredabone
    Joined: Apr 18, 2001
    Posts: 735

    hammeredabone
    Member

    Nice work, thanks for sharing!
     

  5. tdoty
    Joined: Jun 21, 2006
    Posts: 821

    tdoty
    Member

    Great work! Didn't anyone ever tell you that you can't do work like that without a bunch of really expensive tools? If they did, I'm glad you didn't listen!

    Tim D.
     
  6. Haunted Ken
    Joined: May 22, 2005
    Posts: 186

    Haunted Ken
    Member

    This board never ceases to amaze me....

    Great Job!
     
  7. 52pickup
    Joined: Aug 11, 2004
    Posts: 833

    52pickup
    Member
    from Tucson, Az

    Thanks guys...

    and a bump for the night guys
     
  8. Squablow
    Joined: Apr 26, 2005
    Posts: 14,637

    Squablow
    Member

    Doretti Swallow? Sounds like a porno. What is this car? Who made it and what does it look like? Very nice work on the door, by the way.
     
  9. 52pickup
    Joined: Aug 11, 2004
    Posts: 833

    52pickup
    Member
    from Tucson, Az

  10. fab32
    Joined: May 14, 2002
    Posts: 13,985

    fab32
    Member Emeritus

    That's some impressive work. It's amazing what you can do with a few basic tools and a little patience when it comes to sheet metal work.

    Frank
     
  11. Squablow
    Joined: Apr 26, 2005
    Posts: 14,637

    Squablow
    Member

    Bitchin, like an early Ferrari. I'd like to see more on this buildup/resto.
     
  12. happy hoppy
    Joined: Apr 23, 2001
    Posts: 2,332

    happy hoppy
    Member

    looks very good, great job.

    is the new door skin just flat sheet with the top rolled?
    is there any crown in the door?

    thanks!
     
  13. DrJ
    Joined: Mar 3, 2001
    Posts: 9,418

    DrJ
    Member

    I thought I recognized the Swallow part from ealy Jaguar so I googled and came up with this.
    This may better describe the car, and you aren't dislexic, you had it right the first time. (I think it's a porn name too!)
    http://www.team.net/www/ktud/swallowd.html
     
  14. hotrod54chevy
    Joined: Nov 7, 2003
    Posts: 1,590

    hotrod54chevy
    Member
    from Ohio

    um......how the hell is this OT? it's car related and you're doing it to an OLD car.....?
    creepy
     
  15. the-rodster
    Joined: Jul 2, 2003
    Posts: 6,664

    the-rodster
    Member

    That article states that the bodies are aluminum, is it incorrect?

    Anyway, that door sure looks a lot happier :)

    Rich
     
  16. jaybee
    Joined: Mar 3, 2001
    Posts: 268

    jaybee
    Member

    You're right, DrJ, the very first Jags weren't Jags, they were Swallows.
     
  17. banzaitoyota
    Joined: May 2, 2004
    Posts: 547

    banzaitoyota
    Member

    It could be the bodies were constructed like the early Austin-Hea;ys: The cowl with all its compound curves were crafted in AL, and the wings and bonnets were stamped in steel
     
  18. 52pickup
    Joined: Aug 11, 2004
    Posts: 833

    52pickup
    Member
    from Tucson, Az


    The doors are the only all steel panels on the car. The hood and trunk lid are steel structure with aluminum skin, and front and rear fenders are aluminum, and the main body structure is aluminum with a steel inner structure.

    the doors are simple curves, no front to rear crown. these cars are flat sided from the rear of the front wheelwell to the front of the rear wheel well.



    well, I though I might catch some shit for it not being a traditional rod or custom, so I put the disclaimer in so I could say "I told you" if anyone started bitchin

    http://www.jalopyjournal.com/forum/showthread.php?t=108042

    rear fender from this car, took a hit when the right rear tire blew.

    Other than that theres not a whole lot to show, I re-crowned the hood to fit the body better, aligned the trunk, which at first was believed to also need a re-crown, but didnt. I'm just doing the metal work on this car, which is really all I want to do. Maybe some day I will be considered competition for Metalshapes for metal work in Tucson... maybe not. :D
     
  19. metalshapes
    Joined: Nov 18, 2002
    Posts: 10,760

    metalshapes
    Tech Editor

  20. 52pickup
    Joined: Aug 11, 2004
    Posts: 833

    52pickup
    Member
    from Tucson, Az

    thanks, that really means a lot coming from you
     
  21. metalshapes
    Joined: Nov 18, 2002
    Posts: 10,760

    metalshapes
    Tech Editor

    I mean it... Awesome work.

    Call me if you need to compare notes about stuff.:)
     
  22. Tuck
    Joined: May 14, 2001
    Posts: 5,645

    Tuck
    Tech Editor
    from MINNESOTA
    1. Early Hemi Tech

    that turned out fantastic...
     
  23. pimpin paint
    Joined: May 31, 2005
    Posts: 4,939

    pimpin paint
    Member
    from so cal

    Hey,

    Pre war Jaguars were actually known as SS cars-( some mystery as
    to whether SS really stood for Swallow Sidecars) Swallow coachbuild-
    ing started life as a motorcycle side car builder, and moved on to cars.
    The SS handle was changed to Jaguar to avoid the nasty Nazi conatation,
    after WWII, and the Swallow coachbuilding sidecar arm sold off.
    Didn't Doretti use Triumph TR power trains?
    Great lookin door!

    Swankey devils C.C.
     
  24. kustomkolin
    Joined: Jan 1, 2005
    Posts: 160

    kustomkolin
    Member
    from Herts UK

    Great work 52.To do all that by hand is one hell of an achievement!More pics please.Thanks,Kol
     
  25. Chris P
    Joined: Nov 27, 2005
    Posts: 429

    Chris P
    Member
    from Tucson

    Nice work! Turned out real well, im making some quaters for my roadster right now i will have to do a tech on it too.

    -Chris
     
  26. Woogeroo
    Joined: Dec 29, 2005
    Posts: 1,084

    Woogeroo
    Member
    from USA

    nice work.

    -W
     
  27. Dirty2
    Joined: Jun 13, 2004
    Posts: 8,903

    Dirty2
    Member

    Very nice work !
     
  28. abonecoupe31
    Joined: Aug 11, 2005
    Posts: 696

    abonecoupe31
    Member
    from Michigan

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