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  #925  
Old 04-23-2016, 07:50 AM
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Re: Grand Willys project

Just had a chance to work a bit on this. A bit of tedious work, bit but needs to be done if I want it right.

Want to actually bolt the front part of the door in place so I can set the door gaps before deciding how long it needs to be made.


To find the best hinges I clamped them to the table and pushed hard one way and then setting the square in place. Then pulled away from the square and measured any gap. Got two pairs that were only 1mm to 1.5mm total movement at the far end away from the pivot point.


I had a problem that the front gap, even at maximum adjustment, was too tight as only 1.5mm-1/16" before primers and paints. It is not like a 50's on vehicle where you can move the front guard/fender forward to set the forward edge gap.


Another thing I noticed there were low and high spots stopping the door from being perfectly flush along its entire length.


So I cut all the way down the edge of the panel so I could solve both problems at the same time.


I lifted the low spots until perfectly flush with the door.


Also set the door gap to 3mm-1/8" which is the minimum recommended on bare steel.


Continue to set the gap and make sure it was flush all the way to the top.


Checking for flush after tacking.


Welded it by 'tack stacking' all the way in one hit without stopping. Very little distortion as the HAZ was kept small and even. Let it cool naturally as using a air gun or water only hardens the metal leading to cracking and uneven shrinkage.

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  #926  
Old 05-01-2016, 09:09 PM
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Re: Grand Willys project

Still on the fiddly boring bits.


This section of door is the best out of all 4 parts that are going to be used. Had some small spots that I opened up with the die grinder until I could feel and see uniform thickness all the way around.


Cut out fill into pieces one gauge thicker than the door to give some sanding room afterwards.


Welded in.


Need to make a dolly to fit in the narrow space behind the patch so I could planish it. Could only find this scrap piece the right thickness.


A bit of shaping later and it fits well. Can slide it now down to the other end behind the patches.


Came out well enough, and most importantly, the little bit of distortion I had was removed.


The welded edge of the door jamb has been cleaned up and sits flush.


Gaps look better now.
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  #927  
Old 05-02-2016, 07:19 AM
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Re: Grand Willys project


Just placed the door extension into place and worried it looks too long compared to the the B pillar area behind it. This has been something I thought could be the case since I first photoshopped the 7" longer cab.


Always had a backup plan in case I didn't like it at this stage. To shorten the door by 2-3" and double up the B pillar rather than cutting it out and moving it. This will make it much stronger too. Then make a new fill in piece. Is it just me or does it look fine??
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  #928  
Old 05-02-2016, 12:01 PM
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Re: Grand Willys project

looks fine to me but I have a feeling ...... it will be changed
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  #929  
Old 05-02-2016, 07:09 PM
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Re: Grand Willys project

Quote:
Originally Posted by robpp View Post
looks fine to me but I have a feeling ...... it will be changed
Ha ha, you are probably right. If something doesn't seem quite right, I will work it until it is.
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  #930  
Old 05-02-2016, 08:49 PM
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Re: Grand Willys project

This might help picture what I am thinking of changing it too.

This is a rough photo chop of a cab I have made similar cab changes too to what I have done, but have also shortened the door and added the length back into the B pillar.
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  #931  
Old 05-03-2016, 04:56 PM
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Re: Grand Willys project

Proportionally I suppose the B post could be 1/3 of the A panel which in turn is 1/3 of the door.
But that's just me over complicating things.
There is a lot of door and an argument for the B pillar to be more in line with the A panel could be made.
Or in other words



I didn't help at all. 👍


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  #932  
Old 05-03-2016, 08:13 PM
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Re: Grand Willys project

Personally I like the original mock up better. Plus, the bigger you make the B pillar the worse the blind spot will be....
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  #933  
Old 05-14-2016, 09:09 AM
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Re: Grand Willys project


While the citric acid does it's job on some rust for the addition B pillars, thought I would address the bottom door gap. I could only get 2mm and needed 3mm! So I cut off 2mm so I could then leave 1mm of weld plus penetration after smoothing it.


Welded up and now have the right door gap. Funny thing is that it now matches the door on the other side which was factory folded slightly different.


The part of the door I am using to extend the door has some rust issues!


Outer skin looked alright but the backside showed heavy pitting, so folded up a new piece to replace it.


So the whole bottom was cut off to replace it.


Hadn't used the tig all year so had to get my hand back into it. Can see it pulled up on the weld line more than normal as went too slow with not enough amps.


Fortunately this end of the door is pretty flat so clamped it to the table to stretch the weld out flat. Bit tricky under the lip so just slid my hammer along while hitting it with the mallet.


Nice and flat now without any distortion left.


Cleaned up ready for the next stage.


Folded up a new piece for the replacement frame. Made from a single piece but welded where the end folds came together.
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  #934  
Old 05-14-2016, 09:10 AM
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Re: Grand Willys project


Checking for fitment.


Need to put the drain back in again otherwise this repair wont last long. Using a 1mm cutting disc I cut into the corner and along the front edge.


Positioned my stake dolly on the edge where I wanted the fold to go and hammered it over just using a small square faced hammer.


The ends just need a bit of weld which I did with some copper in the slot to stop it filling the front.


The door skin and the back of the new piece was zinc coated before fully welding it in and planishing it flat.


Front face gets coated and backside of the flange to be folded.


Just tapped the flange over slowly working my way along using the bench as the backup dolly.


Repair complete ready to be joined onto the front part of the door once the new B pillar and skin piece is in place and I can cut this to the right width.
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  #935  
Old 05-17-2016, 10:33 PM
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Re: Grand Willys project

New member that just found your thread. I'm glad I didn't have to wait all this time. I got to read the whole thread at my own pace. Now I'm stuck waiting like everybody else. The suspense is killing me.

Marcus you are a true old school craftsman. My father is the same way but with wood. He's 86 now and still remodeling houses. Told me he was going to die with a hammer in his hand so I hid his hammer.
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  #936  
Old 05-18-2016, 08:19 PM
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Re: Grand Willys project

Quote:
Originally Posted by Governor View Post
New member that just found your thread. I'm glad I didn't have to wait all this time. I got to read the whole thread at my own pace. Now I'm stuck waiting like everybody else. The suspense is killing me.

Marcus you are a true old school craftsman. My father is the same way but with wood. He's 86 now and still remodeling houses. Told me he was going to die with a hammer in his hand so I hid his hammer.
Better to die doing what you love for sure. If I should be so lucky to be his age and still doing a trade I enjoy. My father walks around with his dog to watch my progress every week and is 90, so living it through me which is nice too.
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