Carrying on with repairing the N/S cab door over the last few days. I needed to rebuild the style line that the door card sits inside as the PO had made it out of filler. This is the gap I needed to fill. And here is the first repair all welded in and dressed. Much better. I’ll get this bit welded in tomorrow to close it all up. Once I’ve done that I just need to carry out some repairs to the bottom of the frame and the welding on the N/S door frame is done. The bottom on this side isn’t too bad (the other side is going to need a lot more work though - I should be onto it early next week).
Some grade A work going on there @JamesLey, that Clarke tool looks like it's giving you good results! I bought their vice mounted sheet metal bender years ago and it doesn't exactly provide the straightest finish shall we say, OK on small bits though...
More door repairs this morning and out for lunch at the old thatch. Just the bottom corner left to do which will be fun! Sent from my iPhone using Tapatalk
A lot of effort isn't it! Basically the entire bottom seal channel on ours has been replaced in some form. Should finish it this week then get the second one started. Sent from my iPhone using Tapatalk
It basically looks like you stole the pictures from my resto thread! The corner, the bottom and even the original colour! It's uncanny. Good work though, my one piece of advice is make sure the aperture where the window comes out of doesn't open up, mine did somehow a little bit, no major problem but that was my only over sight.
Cheers fella. Yeah there seems to be a strengthening piece in each corner of the window aperture which I'm planning to tack to the inner frame as it seems to have either come away or was never originally spot welded to the frame. Hopefully that'll keep the aperture right, if not I've got measurements to go off anyway. Sent from my iPhone using Tapatalk
And check your new door skins as one of mine the trim holes for the weather strip are rubbish and needed redoing
Folded up another repair for the bottom of the door tonight. Cleaned up and etched the wing mirror brace bar. Sent from my iPhone using Tapatalk
Lower corner done now. Nearly there with this door (sick of the sight of it tbh!) Sent from my iPhone using Tapatalk
After many, many, many hours I’ve finished the welding on the bottom of the inner frame for the N/S cab door. I had this final gap to fill where the frame curves round to join the door skin: Quite a fiddly bit to make, I ended up doing it in a few bits, but the end result looks fine and the skin fits well around it: Then finally a thorough cleanup with Strip & Clean discs and wire wheels, and a coat of zinc primer. Much better! I’ve not ground the welds down on the inside as it’ll be hidden when the skin is on, but i’ll put some seam sealer on them before I fit the skins. The outside will need a skim of filler along the bottom when I get round to the shaping stage. Not bad considering it looked like this before: Now to start the other side!
Made a start on the O/S cab door this week. It’s in slightly better condition than the other side, apart from the bottom which is in a terrible state: Schofields repair cut down and clamped in while I repair the brace bars: Both bars repaired: And made a start on the repair for the wing mirror bar:
