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Reskinning Doors

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dpaulson:
Cranman, when you've reskinned the doors with 24ga, are you simply welding a new skin on or are you folding the skin over the angle iron frame.  How hard is it to keep the door frame shape if you are folding the sheet over the angle's edge.  How hard is it to fold the radiused corners.

Cranman:
You have to cut the piece a bit larger than the frame and just form and pound the metal over. At the corners you have to cut even closer in a kind of semicircle. If you can get a look at a factory door you'll see how much to leave. You need a big sturdy flat table to work on and when Cam did mine I held one side up a bit so the area he was forming was flat on the table. He mostly used a big ball pean hammer held close to the head to do the pounding. Since the doors aren't flat you  have to keep the metal flat on the table. It really goes on well. You have to adjust the door frame angle iron to fit perfectly before you start. I haven't had any experience replacing the inner metal of the doors. When we were done reskinning Cam lined the inner door with the birch plywood right through, then did the framing with 7/8 Maple for the part below the window. The frame below the window was champhered out so the plywood part was even with the metal and quite pleasing to the eye. If you have to do your rad door, do it first to get the hang of it.

dpaulson:
That may be my job for next weekend. I can only get 18ga sheet, but I have a brake so I can at least get the flanges bent to a 90 deg.  I'll try the rad door first, to see how difficult it may be.

the old trucker:

--- Quote from: dpaulson on May 31, 2010, 12:49:40 pm ---That may be my job for next weekend. I can only get 18ga sheet, but I have a brake so I can at least get the flanges bent to a 90 deg.  I'll try the rad door first, to see how difficult it may be.

--- End quote ---
 
    Dpaulson did you have a go at reskinning the doors yet. I know your taking pics of all this. I'm interested to see how it is done.

dpaulson:
No, not yet.  I got a bit sidetracked. I have been concentrating on more of the interior stuff. I have the driveshaft apart to install a brake rotor and caliper.  The alternator had been put on the passenger side of the motor, so I need to relocate that to the other side so the power steering pump can be installed in its place.  This weekend I hope to have the steering cylinders in place and the steering hand pump installed.

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