Re: Project Family Hauler
 

Good stuff man. Looks like you might have to go with a bear claw style latch.

Re: Project Family Hauler
 

I am thinking about that. Will try the fitment of factory latch first. Want it to look like factory parts to match front. Or I will change fronts so they are all the same.

Re: Project Family Hauler
 

Got about 4 hours in yesterday. Wife is working this weekend and I am watching our 2 year old. I would have her help work on the suburban but she doesn't like loud noises.

Had to reshape the bottom of the door. The front of the rocker panel is fitted for the front curve of the door, but I used the rear part of a passenger door so the body contour is right but the curve is different on the bottom. So I had to blend the two.

Not only do I have to design the parts, I have to make them and put them together. This is the reason for the slow progress. This is the first time I have done something this custom. I spend a lot of time thinking about how I need to make a part.

http://i763.photobucket.com/albums/x...n/DSCN2807.jpg
http://i763.photobucket.com/albums/x...n/DSCN2808.jpg

Also found the original latch will fit. Tested the door skin and it lines up so the handle will work. Very tight inside. Am going to have handles together like old Lincolns. Using original truck handles.

http://i763.photobucket.com/albums/x...n/DSCN2805.jpg
http://i763.photobucket.com/albums/x...n/DSCN2806.jpg

Re: Project Family Hauler
 

Got to work on the suburban today. Fitted the door skin. Found the inside needed to be rearranged a little so everything lined up. This is the new view.
http://i763.photobucket.com/albums/x...n/DSCN2813.jpg

Gray door is the 4th door

http://i763.photobucket.com/albums/x...n/DSCN2817.jpg

Ended up mixing the door skin with the side of the suburban to get the curve right.

http://i763.photobucket.com/albums/x...n/DSCN2815.jpg

Distant view, crazy to look at.
http://i763.photobucket.com/albums/x...n/DSCN2818.jpg

Maybe tomorrow I will start fitting the window frame.

Re: Project Family Hauler
 

wow thats cool

Re: Project Family Hauler
 

Got the door frame in shape. Had to fit the angles to the suburban. Window rolls up and down. Corner window fits. Got the inside handle installed with linkage. The frame is straight. Just looks curved in picture.

http://i763.photobucket.com/albums/x...n/DSCN2820.jpg

http://i763.photobucket.com/albums/x...n/DSCN2822.jpg

http://i763.photobucket.com/albums/x...n/DSCN2821.jpg

Relocated the inside handle. Everything is connected to release the door.

http://i763.photobucket.com/albums/x...DSCN2826-1.jpg

Close up of window. The skin gets closer at this window.

http://i763.photobucket.com/albums/x...n/DSCN2824.jpg

Rear view of door open

http://i763.photobucket.com/albums/x...n/DSCN2819.jpg

Front view of door open

http://i763.photobucket.com/albums/x...n/DSCN2826.jpg

Still need to fill the gap between the doors. Passenger side is extended from the factory to fill transition.

http://i763.photobucket.com/albums/x...n/DSCN2823.jpg

Also started to finish off the door jamb.

http://i763.photobucket.com/albums/x...n/DSCN2825.jpg

More to come soon.

Re: Project Family Hauler
 

that looks good hope to see the gap closed a little more but i probably couldnt do what you did in such a small amount of time you got seious fab skills:metal:

Re: Project Family Hauler
 

Thanks. I have had this suburban for 5 years and have been working on it for over a year. The first 4 years was just getting the project done in my head. Making a door is the hardest thing I have done. You need to make everything fit from 12 different angles. It wouldn't be as hard if I didn't need to use hinges. Just this weekend I spent 16 hours fitting the door into the opening. It was already started and not even close to being finished. Still have lots of welding and grinding to do. Also need to hammer & dolly the skin. Some of the curve is gone around the weld.

Re: Project Family Hauler
 

very cool project! Just found it but read the thread and looking forward to following the progress. Great work so far!

Re: Project Family Hauler
 

Very nice work!

Re: Project Family Hauler
 

Slight distraction. Our friends were over for dinner and this car came flying down our street in reverse chasing some kids that were on the sidewalk. The driver wasn't looking and hit our friends Jeep Grand Cherokee at about 40 mph. After I chased them for about four blocks (I was on foot) they realized I had their license plate # and came back.[IMG]http://farm5.static.flickr.com/4111/...d09cf21248.jpg[/IMG]

[IMG]http://farm5.static.flickr.com/4088/...184aeb47f3.jpg[/IMG]

No one was hurt but the kids in the car had to be hurting today.

Re: Project Family Hauler
 

It might not look like I did much but it took all day. Finished around the door jamb at the top. Got the pieces from spare cabs so the shape was correct from the door seal to the outside skin. Plug welded the lip for the door seal.
[IMG]http://farm5.static.flickr.com/4084/...8eeb20fc3d.jpg[/IMG]

[IMG]http://farm5.static.flickr.com/4111/...1e21c45f23.jpg[/IMG]

Front and back door and the B pillar.
[IMG]http://farm5.static.flickr.com/4108/...02d3f33236.jpg[/IMG]

Back window frame.
[IMG]http://farm5.static.flickr.com/4112/...090762e6ee.jpg[/IMG]

Close up. Inside corner tough to grind.
[IMG]http://farm5.static.flickr.com/4085/...8fcc11fc52.jpg[/IMG]

B pillar with door seal lip.
[IMG]http://farm5.static.flickr.com/4091/...0f7e65cfef.jpg[/IMG]

Painted it because the rainy season has started and it is humid. Don't want surface rust to start in bad areas.

Re: Project Family Hauler
 

nice work sorry about those people

Re: Project Family Hauler
 

nice work...really coming together!

Re: Project Family Hauler
 

Lookin' good.

Re: Project Family Hauler
 

Hey Travis i gotta hand it to ya, i think what your doing is way over my head and your making some great progress! I see my and your work shop is basicly the same, a 10X20 car cover, pita isn't it! :)

I need to get some panels replaced in my truck soon but admittedly i little hesitant to start just yet, reading these threads are building my confidance tho...

Welcome from Spanaway! I live close enough to Puyallup S Hill I call that my home. Subscribed!

Re: Project Family Hauler
 

very interesting project, but the fab work is looking good ;)

Re: Project Family Hauler
 

We are neighbors. This is why the suburban is under a car cover. The garage is already occupied. And yes I need new wheels for it, these are very dated. I bought them in 1994 when I was still in high school.

http://i763.photobucket.com/albums/x...kup67man/2.jpg

I didn't think I would be able to do it either but I had $100 invested in the suburban so I could afford to mess it up. The car cover cost more.:lol:

After 4 years of looking at it I started cutting.

Re: Project Family Hauler
 

[QUOTE=pickup67man;4200846]This is why the suburban is under a car cover. The garage is already occupied.

Yea mine is occupied too, 3 motorcycles and the 2 small doors arn't big enough to even get my truck inside unless i find smaller tires, but even then if i got it in i'd have to crawl out the window unless i ripped out a work bench and some shelves, that would be a mess. LOL! The good news for me tho is i can cram the bikes to one side and i can utilize a portion of 1 side to do some work if need be.

Re: Project Family Hauler
 

I didn't say my garage was big. The back wall is notched and I back the truck until I hit the carpet that is on the siding. Then I have 1" between the front bumper and the door. I have to crawl out the passenger door to get out of the truck. Watch the video. I tried to link it better but you need to click on the link to see it.


Truck in garage by pickup67man - photobucket

Re: Project Family Hauler
 

LOL! yea i knew you had a smaller garage from the picks in this thread.. That a clever use of a support beam under that window! tight fit!

Re: Project Family Hauler
 

Worked on it yesterday for about 5 hours and it looks the same. The door wasn't fitting very well. Cut some welds out twisted the door into shape and welded it back together. Did some hammer and dolly work on the skin. The door fits better now. It sits close to the weather strip and the body lines flow well. Also had to rearrange the hinges a little. When I opened the door it looked like it was sagging, but the pivot point was wrong on the upper hinge.
Now before anyone says anything about pics I already said that after all that work it looks the same( at least in pictures)

Re: Project Family Hauler
 

What no pic's?? LOL!

Heres my latest:
http://67-72chevytrucks.com/vboard/s...=1#post4212828

All that work gave me a craving for a Dons Drive In Double Cheesburger on a french roll (forgot the name) but it was too late and now here i am at work... :)

Check this link out if ya need parts:
http://67-72chevytrucks.com/vboard/s...2&postcount=72

Re: Project Family Hauler
 

Those parts would be good but I have the rare 4 door suburban, he is only selling 3 doors.:lol:

Re: Project Family Hauler
 

Ok just found the thread and he's got lots of stuff..