Re: LFD's 4dr Burb Build
 

Well the door is turning out good and should be finished by Sunday if all goes well. I had to take a slice out of the door skin to get the profile just right. I decided to use my Tig welder for this job (guess I was feeling Lucky) but I have never really Tig'd body panels just some brackets and "Play stuff". I guess luck was on my side because it turned out great and after some time of Tacking, Dollying, Tacking, Dollying and after about two hours it will only need a few good cotes of fill primmer and blocking.

Kevin
LFD Inc.

http://i16.photobucket.com/albums/b2.../Tahoe64-1.jpg

http://i16.photobucket.com/albums/b2.../Tahoe62-1.jpg

http://i16.photobucket.com/albums/b2...ln/Tahoe68.jpg

http://i16.photobucket.com/albums/b2...ln/Tahoe66.jpg

http://i16.photobucket.com/albums/b2...ln/Tahoe65.jpg

Now I am starting on the rear jamb before I tackle the upper window rail.

http://i16.photobucket.com/albums/b2...ln/Tahoe67.jpg

Re: LFD's 4dr Burb Build
 

Nice work ,and craftsmanship.

Re: LFD's 4dr Burb Build
 

badazz az alwayz!!! Stop making it look so easy... Im starting to think I can do it too...:fro:

Re: LFD's 4dr Burb Build
 

What's the blue stuff on the door?

Do you dolly after each tack, or after a series? Is the procedure with the TIG similar to that of the MIG? I also have a TIG that I've only played with a little bit, practice pieces and a few tube adapters. I want to get good with it, but can't seem to find the time to practice.

Re: LFD's 4dr Burb Build
 

But it is real easy. All I do is push these projects into the shop, close the door and it just happens. Doesent your shop work the same way:lol: But really thanks it has been along road but one anyone can take. Just give it a shot and it will start getting easier.

The blue stuff is a machinist dye used for doing layout on steel. It is super thin almost like a stain and not a paint. I then take a body file and go over the area to knock down any hi spots then I run a long board with 80 grit over the area to see were things are. Then I know what to do from their to get the best metal finish that I can do at this point in time because it is a new process for me.

Tig is far superior to Mig for doing body work because the welds are softer and they can be worked with a hammer and dolly much better then Mig can. Also a proper Tig weld is much flatter then Mig and this means less grinding to get it flat and that means less heat and less work hardening. As far as do I hammer and dolly each tack or after a few it just depends on what it is that I am doing.

Kevin
LFD Inc.


Well it is really starting to take shape now. I started and finished the upper rail tonight and started tacking the door together. I still have allot of work to do before it is finished but I can sure see the light now.

http://i16.photobucket.com/albums/b2...ln/Tahoe69.jpg

I used shims for spacers to keep the gap even.

http://i16.photobucket.com/albums/b2...ln/tahoe70.jpg

More Tig welds.

http://i16.photobucket.com/albums/b2...ln/tahoe71.jpg

Re: LFD's 4dr Burb Build
 

Good work, cant wait to see it done and painted!

Re: LFD's 4dr Burb Build
 

So for the upper rail I took two Burb door rails and welded them together. The front section is the rear of a passenger front door and it lined up great. Then the rear of this rail is the rear of a driver side rail and I had to slice the lower section that tucks into the door to get some angle on it so it would slide into the new door. Then the upper corner I just cut halfway through it on the top and bottom so it would bend to the correct angle for the opening.
Then I double checked the fit with it in the door for the first time.

http://i16.photobucket.com/albums/b2...ln/tahoe72.jpg

Made sure everything cleared when open and shut.

http://i16.photobucket.com/albums/b2...ln/tahoe73.jpg

I had to extend part of the lower rear rail so it tucks inside the door. It was about a 1/2" to short once I leaned it forward it had to grow just a bit.

http://i16.photobucket.com/albums/b2...ln/tahoe74.jpg

Once I was sure it all worked I pulled it apart and prepped any area that I could not get to later or that was sandwiched against another layer. I used a anti rust primmer that is also a weld through product.

http://i16.photobucket.com/albums/b2...ln/tahoe75.jpg

http://i16.photobucket.com/albums/b2...ln/tahoe76.jpg

http://i16.photobucket.com/albums/b2...ln/tahoe77.jpg

All back together with the upper rail tacked in place until the rest of the door is finished up just in case it needs some adjusting.

http://i16.photobucket.com/albums/b2...ln/tahoe78.jpg

http://i16.photobucket.com/albums/b2...ln/tahoe81.jpg

http://i16.photobucket.com/albums/b2...ln/tahoe80.jpg

http://i16.photobucket.com/albums/b2...ln/tahoe79.jpg


Now I need to finish up the hinge side of the door just so it looks finished and like the passenger side. Then I will cut out the inner door panel area and weld in the stock Burb inner panel so I have the window regulator and vent post mounting area. Then I will make the new lock rods and pivot mounts. Once the window rolls up smooth I will be converting it to power windows but figured this is the bast way to get their.

Kevin
LFD Inc.

Re: LFD's 4dr Burb Build
 

Oh Yeeeeya!!! Like it was meant to be. :metal:

Re: LFD's 4dr Burb Build
 

Well I spent another 5hrs slicing and dicing today to get the windows and regulator in and working. I also have the old inner quarter panel cut and fit now as an inner door panel. I still have some playing with the window to get it just right and I have not bolted in the top of the window divider yet not to mention about 4' of Tig welding on that inner structure. I should have it close to being done by Sunday night, I hope;)

Kevin
LFD Inc.

http://i16.photobucket.com/albums/b2...ln/tahoe82.jpg

http://i16.photobucket.com/albums/b2...ln/tahoe83.jpg

As you can see in this pic the inner structure from the burb works well after alot of trimming and fitting. I still have the door handle area and the door lock to do.

http://i16.photobucket.com/albums/b2...ln/tahoe84.jpg


Frizzle Fry here is the primmer I have been using.

http://i16.photobucket.com/albums/b2...ln/tahoe85.jpg

Re: LFD's 4dr Burb Build
 

subscribed incredable work as always..

Re: LFD's 4dr Burb Build
 

Another 6hrs down and way to many more to go! I sectioned the outer door edge were the window felts go so it would match the pass side and not drag on the glass. I just cut sections out of a donor front door and Tig'd then in place. Then I made the cradle for the fixed vent window and installed the inner door handle latch mounting area. Then 3hrs of fun started when I had to rebuild the door lock system in reverse but it is done and works great.

Their Will not be any progress until next weekend because I am taking off in an hour to head down for my class this week with Lazzy to learn the English wheel, power bead roller and other panel fabrication tools. I will be taking pics;)

Kevin
LFD Inc.


http://i16.photobucket.com/albums/b2...ln/tahoe86.jpg

http://i16.photobucket.com/albums/b2...ln/tahoe87.jpg

http://i16.photobucket.com/albums/b2...ln/tahoe88.jpg

http://i16.photobucket.com/albums/b2...ln/tahoe89.jpg

http://i16.photobucket.com/albums/b2...ln/tahoe90.jpg

http://i16.photobucket.com/albums/b2...ln/tahoe91.jpg

http://i16.photobucket.com/albums/b2...ln/tahoe92.jpg

http://i16.photobucket.com/albums/b2...ln/tahoe93.jpg

http://i16.photobucket.com/albums/b2...ln/tahoe94.jpg

Re: LFD's 4dr Burb Build
 

Whoa, good work man! So many hours for what I though was a simple little thing.

Re: LFD's 4dr Burb Build
 

Yep in theory it should be a simple to medium thing to do until you get into it. Then if you want to make it look like it rolled off the assembly line then it takes on a whole new time frame.

Kevin
LFD Inc.

Re: LFD's 4dr Burb Build
 

I about to start playing with my spare doors ;) Thanks for the info on the primer. What's the blue stuff?

Re: LFD's 4dr Burb Build
 

It is just layout ink or machinest dye. If you need any detailed picks for the spare doors let me know, I have a few laying around;)

Kevin
LFD Inc.

Re: LFD's 4dr Burb Build
 

Man Kevin, she is looking good.

Re: LFD's 4dr Burb Build
 

This one seems to be going faster than the one you did on the pickup. Is it different or did you just learn from the first one?

Re: LFD's 4dr Burb Build
 

Both! Plus this is not damaged or rusted like the truck was. But I am also going to the extra step on this one and making it as stock as posible.

Kevin
LFD Inc.

Re: LFD's 4dr Burb Build
 

The burb is looking good. I like the Cabrio at Dominator as well.

Re: LFD's 4dr Burb Build
 

Watching...:exit:

Re: LFD's 4dr Burb Build
 

Dude, thats awesome :metal:

Re: LFD's 4dr Burb Build
 

So here is just a tease of what I made while in class. In most pic's you can see the flat plate I started out with, it was suck a blast! Now I need to sell Low-Buck so I can afford the tools I need to build more and more and more......

Kevin
LFD Inc.
Learning curve or a fender as Lazzy calls it.

http://i16.photobucket.com/albums/b2...rln/lazzy6.jpg

http://i16.photobucket.com/albums/b2...rln/lazzy5.jpg


Alum hood scoop.

http://i16.photobucket.com/albums/b2...rln/lazzy4.jpg

http://i16.photobucket.com/albums/b2...rln/lazzy3.jpg


Rear quarter panel.

http://i16.photobucket.com/albums/b2...rln/lazzy1.jpg


A pillar.

http://i16.photobucket.com/albums/b2...rln/lazzy2.jpg


This is the start of the door.

http://i16.photobucket.com/albums/b2...rln/lazzy8.jpg

http://i16.photobucket.com/albums/b2...rln/lazzy9.jpg

Re: LFD's 4dr Burb Build
 

Well good news my electric life power windows showed up today. I ordered one set to check out because they do not make a set for the rear windows of the burbs only the front's. After a few minutes of looking and a few quick measurements I do believe they will work great in the rear doors with very little modifications. If I get a few projects done Thursday I will do the mod and see how well they work. Electric life is a direct bolt in for the fronts of the Burbs, truck and blazers and very soon my rear side doors:metal:

And yes I will show a step by step to mod these for anyone else wanting power windows in all 4 locations.

Kevin
LFD Inc.

Re: LFD's 4dr Burb Build
 

I Bet that was a Blast making those Part's, Just Think how much Time & Effort you will be saving with Your Creation's once you get the Equipment.............

Thank's for Sharing the Pics...........

Rick

Re: LFD's 4dr Burb Build
 

Yes it was a blast! Here is the end result of my first 3 days. I can't wait for the 5 day class;)

Kevin
LFD Inc.

http://i16.photobucket.com/albums/b2...ln/lazzy18.jpg

http://i16.photobucket.com/albums/b2...ln/lazzy20.jpg

http://i16.photobucket.com/albums/b2...ln/lazzy22.jpg

Re: LFD's 4dr Burb Build
 

Dayum, sounds to me like that class is well worth it, how much does it cost?

Re: LFD's 4dr Burb Build
 

Nice work Kevin. I met Lazze a couple of years ago at the GNRS. I loved the fact that you didnt have to work the steel over a bag before you started wheeling, keeps the noise down, neighbors happy. He sure is proud of his $tuff.

Re: LFD's 4dr Burb Build
 

$1350.00 for the 3 day class and $2350.00 I think for the second class and it is a 5 day.

Yes keeping everyone happy is the key to good neighbors and your right he is very proud of his stuff but I have never used equipment that responds as fast as his does. His Bead roller is also very, very adjustable and that is key to good panels when all is said and done.

Kevin
LFD Inc.

Re: LFD's 4dr Burb Build
 

Are you gonna finish that coupe or leave it as art?

Re: LFD's 4dr Burb Build
 

Ron Covell rules! I think I have every movie he has ever made. Course they are just the basics. Heck I even got the motorcycle ones and I am not into bikes.

Re: LFD's 4dr Burb Build
 

This will stay as ART! I can always build another set for a full car after I have the rest of my set up. I can also use it as a template for the next one because I made sure every part is dead on so it could be finished down the road. But since now I have the basic skill to do it again I think it would just be way too cool to have this as ART.

I have allot of Ron's stuff as well. This body side was made in a class I had with www.Lazze.us , I had Ron's 2 day class a few weeks ago. I am a firm believer in you can never learn too much so I am always trying to find new info.


Burb new! I modded one window regulator today and I will do the other side on Friday for a How-To write up. I installed the one I did today and it worked great for one revolution until the glass came out of the old bottom Chanel, no fault of the regulator kit just old parts but it did work great that one time.


Kevin
LFD Inc.

Re: LFD's 4dr Burb Build
 

Awesome fab work man. How do you have your tig set up to weld sheetmetal? (Electrode size, rod size, amperage) When you hammer and dollie afterward,are you stretching the weld spot back out? I cut down my long bed like you did with low buck, and had a hard time keeping things straight. I still have one corner that I nned to work on.

Re: LFD's 4dr Burb Build
 

Man that is some awesome work you do....:metal:

Re: LFD's 4dr Burb Build
 

For the most part I try and match my rod size to the metal size. For sheet metal I use 1/16th (orange) rod with .023 or .035 filler wire. Yes I stretch the metal after welding because any time you weld it will shrink the weld area. So even if you get a "Pucker" out side your work area it is still from right at the weld location. Also keep in mind any low spot you have is surrounded by a high spot so it can get tricky figuring out what is needed.

Thanks I try and I am always learning and it is great I can show my progress here and other people and get ideas from it and I get allot of ideas from all of you as well.


Kevin
LFD Inc.

Re: LFD's 4dr Burb Build
 

Well not much progress but I did get the door gap adjusted and then leaded in. Next wil be pulling the door back off and finish welding the inner panel and the front edge.

Kevin
LFD Inc.

http://i16.photobucket.com/albums/b20/rokcrln/lead1.jpg

http://i16.photobucket.com/albums/b20/rokcrln/lead2.jpg

Re: LFD's 4dr Burb Build
 

I got allot done today and would have finished the 4th door but I ran out of gas for my TIG. I started off by adding the second skin to the front of the door edge. This is to add strength to the front edge just like the factory did. Since mine did not have the factory door edge I had to make it this way. I first welded the edge all the way up the door making sure not to warp anything. Then I added an 1/8" Tig rod to the edge of that to give a thicker profile so their is more for the paint to stick to and to give a bit more metal to to scribe for my door gap. Then I sprayed some blue die on the edge of the door so when I scribed my 3/16" gap it would be allot easier to see and grind. After that was done I started welding up the inner door panel up until I ran out of welding gas.

Kevin
LFD Inc.


http://i16.photobucket.com/albums/b2...n/tahoe100.jpg

http://i16.photobucket.com/albums/b2...n/tahoe101.jpg

http://i16.photobucket.com/albums/b2...n/tahoe102.jpg

http://i16.photobucket.com/albums/b2...n/tahoe103.jpg

http://i16.photobucket.com/albums/b2...n/tahoe104.jpg

http://i16.photobucket.com/albums/b2...n/tahoe105.jpg

http://i16.photobucket.com/albums/b2...n/tahoe106.jpg

http://i16.photobucket.com/albums/b2...n/tahoe107.jpg

http://i16.photobucket.com/albums/b2...n/tahoe109.jpg

http://i16.photobucket.com/albums/b2...n/tahoe108.jpg

Re: LFD's 4dr Burb Build
 

Looking Good, Between you , Hart & Frizz You Have Set the Bar Pretty High for any one Even Thinking of a Burb Build:lol::lol::lol:

Rick

Re: LFD's 4dr Burb Build
 

Your thread is very inspirational. I learn a lot by watching others. My gaps on my truck are all over the place. Im trying not to look at them for the moment :) maybee they will correct themselves... lol. just kidding. Keep up the good work and keep the pictures coming.

Re: LFD's 4dr Burb Build
 

Thanks Rick, real soon someone else can add their name to this list ;)

Kevin
LFD Inc.

Re: LFD's 4dr Burb Build
 

The part I'm waiting to see is a pancaked roof. A beaded one would be very slick looking.