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Looking good!
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Here are the pics of the drivers door. There is much less surface rust on the inside and the corners are better. Same procedure as the other door. The one shot shows the pie cuts and manipulation to make the sides match up. The corners on the original are sharper than the patch so I had to get them to blend together. I had to do this on both doors. Now that I've checked the fit I get to finish weld the whole thing. |
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Your repairs are lookin' great! Having doors without giant holes in the bottom is so nice. There's considerably less road noise even without adding any sound deadening
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I've got to repair the bottom of my doors...I just got my welding setup...time to start practicing before I do the doors. What adjustments did you have to do to the bottom patch panel to make it work better? Love the drain holes!
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I've got the welding and grinding done on the inner patches of both doors. I am going to get some epoxy primer on both sides of them before before continuing. So I'm working on setting them up to spray today. I'm also trying to set up scaffolding of sorts so I can get to the front of the roof to start installation of the roof lights.
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Looking good!
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Well, I've been real lazy about posting my progress but I have made a lot of progress and I've tried to check in on others work almost daily. By the way. thanks Karl. I have the doors epoxy primed and ready to continue with some more bodywork, I made a redneck scaffolding and got my roof lights wired, and I revisited my attempt to fix the passenger side rear corner of the hood that I totally botched the first attempt. It was so bad I'm embarrassed to show pics so I covered it up with a rag so I would quit being obsessed about it and let it go. My biggest dilemma was finding a patch. Trying to find a decent hood patch was not working out. I decided to cut out the bad patching job while looking for a solution. There are a lot of complex curves involved so I just didn't want to tackle fabricating what I needed.
So I'm sitting looking at the hole in the hood and I had an idea. If you take the cowl extension from the opposite side that you are working on, you can drill a few spot welds out (this gives you a perfect back lip) and then carefully cut the rest of the brackets including the extension. This gave me an almost perfect 12"x12" patch for the corner. I'd be surprised if nobody has thought of this but it worked out great. I had a bigger area that I needed to replace. I still had pieces of my donor hood to extend the patch another 3" or so. I welded the patches together and also used a piece to extend the bottom lip(the cowl extension has about a half inch lip so I welded a piece in to extend the lip to match the rest of the lip). I am very happy with the fit and I started to tack things in place. Here are some pics of the project. |
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Brilliant idea about the cowls! How did you wire the lights? Are they wired to your regular lighting or do you have a separate switch?
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Necessity is the mother of invention right?
The new patch looks great! Once it's done, no one will know that it was from the cowl unless you tell them |
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I finished the welding on the hood today except the bottom edge. Since I don't posses the ability to weld upside down. I'll take care of it when the hood comes off for paint. |
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I've got the entire top of the hood to strip, bodywork, and epoxy.
Here are some pics of the wiring of the roof lights and my scaffolding (what a crazy setup but it worked) made with my extension ladder. One end on my workbench and the end held up by my overhead by my crane and various straps to stabilize that end. It worked fine to get to the front of the roof. I had totally given up on snaking the power wire from the roof down into the cab. I mean every possible way and with no luck. I made an executive decision to go ahead and drill the hole in the roof where the center light power wire is and work from there. After drilling the hole it took about 10 minutes of fishing around and I was able to run the wire down the rear driver corner where the courtesy light comes down. I was then able to to get the other two lights wired. I've got the connectors hooked up so all I have to do is plug in the pigtails when I mount the lights. I need to drill a few more holes to mount the lights. I've got LED bulbs and new pigtails for the lights and I've got some gasket material on order to go between the light assembly and the roof. I hope it works. |
Re: pdx-sanity66
One crazy thread with very helpful information! Subbed!
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Killer idea on using the cowl corners to fix the hood... consider it stolen.
Great work my friend, stay after it. |
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I'm still working on the cab lights. I'm trying to find some suitable rubber sheets to make the mounting gaskets. I've tried 2 different types that didn't work and I've got another ordered that might be correct. We'll see.
I am continuing work on the doors. I got some filler applied and smoothed out on both doors and another coat of epoxy. Yesterday I did a small amount of filler on a couple of small places and the the next step is some slick sand. These pics are before the epoxy and final smoothing before the slick sand. |
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For cab light gaskets I was thinking that rubber roll roofing material they use on commercial flat roofs. Certainly UV resistant cuts easily with scissors, the right thickness, should be able to get some free scraps.
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Soft foam rubber fender covers, they're about 1/16" thick... might work.
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Here are the hinges anxiously waiting for the new hinge pins and bushings. I didn't get around to getting some spraying done but the corner patch is done. here is the first pic of the patch and the piece that I cut out. I have now sanded the entire pass. door and it is ready for another coat of epoxy. I also did a little work on the door pillars on both sides of the cab and they are also ready for epoxy and then slick sand. The outside of the driver door doesn't need any further work except sanding.
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I'm posting the pics of my bed steps for an interested member
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I finally found the seal material for the roof lights so I have completed the mock up of the lights and tested them. They work. After some decompression on the work on my doors I have continued with them. They have been patched, smoothed, end received a good coat of epoxy. I got the new hinge pins and bushings so the hinges have been rebuilt. I installed the Honda door seals and I've been working on aligning the doors. I found that I had 2 main hinge bolts on the drivers door were stripped, Ugh. It was actually the nuts in the body panel that were stripped, but upon closer inspection I found that rust was not the reason they stripped. the nuts looked clean. I decided that before doing anything radical that I would try tapping them out to a 5/8" bolt from the 9/16". I used a 3/8" drill bit and drilled out the old threads. I also enlarged the oval hole in the body so the larger bolt could move freely. I then tapped the hole. It worked perfectly. I will enlarge the oval hole in the hinge so the bolt will move freely there also. This is a matter of removing 1/32" from each side. So I hope to get the door back on today and continue the alignment. I'll post up some pictures later today
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Here is a picture of the roof lights all lit up. I have decided to put them on their own power with an on/off switch on the dash. Also some pics of the driver door work on the hinges.
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Re: pdx-sanity66
Looks great! I love the lights on the roof. I want to do that on my GMC build.
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Really like the bed steps, might be tempted to hide the rather poor conditions my bed sides....
Nice work. P. :D |
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I have got the doors aligned pretty close except the bottoms need to be tweaked about 1/4" in to align correctly. I also got the door latches on to help with the alignment. They are working great. I still need to get a couple of outside handles as my originals have some pitting. I decided to take a break on finishing the doors and start on finishing the hood. I got the remainder of the top stripped. It's ready for bodywork and epoxy. I'm also trying to get rid of a small tin canning on the driver's side.
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I am making some pretty good progress on my Sanity and I can see the end in sight. Glass is the next biggy so I need to get the top ready to paint white and get that done. at that point it will be drivable which is the priority right now. I want to drive this truck further than around the driveway. I have said that I won't be getting another of these trucks but once in awhile something come up that you can't let get away. I drove about 90 minutes north to Mammoth, AZ and this is what I ended up buying. C60 dually with large utility bed and some decent sheet metal, good glass, nice hood and doors, no engine but all drivetrain is there. Now I have to find a way to get it back to Tucson. Guess how much?
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Hmmm, a case of beer? :barn: That's gonna need a big trailer :lol:
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Cool big truck! $500?
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I wired up and installed the on/off switch for the roof lights but I was not happy with the way it looked on the dash so I am modifying a choke knob for the horn button to fit into. I got the knob done and now I am modifying the connection to the dash.
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Slick! That will blend in better with what's already there...good idea.
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Wow! That's a great idea.
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I love the switch for the roof lights! Great job...and awesome buy on the c60!
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