Re: Project Family Hauler
 

Only got one day to work on the suburban this weekend. And got a late start, not a lot of energy today. So I didn't get too much done.

Are they ever going to stamp replacement rocker panels that fit correct. I know mine has been modified a lot but I still had to fix the part under the front corner of the front door. If I didn't do this the corner of the door would hit the rocker panel.
http://i763.photobucket.com/albums/x...n/DSCN3383.jpg

Then I had to finish up where I cut the top to fit better. I got so used to seeing it the way it was I almost didn't notice it wasn't finished.
http://i763.photobucket.com/albums/x...n/DSCN3384.jpg

Then I decided to grind more welds on the B pillar. I have put off this part for nearly 3 years. Don't know why, its not any worse that everything else I've been grinding.
http://i763.photobucket.com/albums/x...n/DSCN3385.jpg

Re: Project Family Hauler
 

Keep at it! Always good to make some progress....I'm headed out to my garage now ;)

On the rockers, I've had aftermarket ones fit perfect w/ no mods needed and the same brand rocker need a lot of work to fit the next truck...I think it's a lot to do with how our trucks were built in the first place...not much QC....

On my shop truck the passenger rocker is factory and the door closes perfect and has great gaps...but every time I shut the door there is a little streak of rust from where it actually hits the painted rocker...the bottom of the door is rusty but not out of shape so just the rust scale makes it hit the rocker....showing how tight it was from the factory...

Re: Project Family Hauler
 

Wow, late night working in the garage. It was almost 5 PM here when you posted. At 8 PM I wouldn't be motivated to get dirty unless I was getting close to a deadline.
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Re: Project Family Hauler
 

Just cleaning up some parts tonight...my wife and girls were at a baby shower and the race and games I watched were over ;)
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Re: Project Family Hauler
 

Great progress!

Re: Project Family Hauler
 

looking good !

Re: Project Family Hauler
 

Great work! The rocker is looking awesome!

Re: Project Family Hauler
 

Thanks. It makes me feel good when I get compliments from guys with awesome trucks.

Need to buy some more POR15 for the backside of the rocker and inside of the door skin then I can close up some stuff
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Re: Project Family Hauler
 

I spent this weekend with so many excuses that I didn't get much done. I blame too much turkey on Thursday.

The top of my B pillar wasn't right. There needed to be a rubber bumper there and wasn't enough room. So I cut and fixed what was wrong. Don't know how I was off when I did it but that is my way (a little off).
http://i763.photobucket.com/albums/x...n/DSCN3386.jpg

The door is really flexible with out the skin attached. I can twist it 1/2" with just my fingers. This also affects how the body lines match up. This is where I'm at with lining up.
http://i763.photobucket.com/albums/x...n/DSCN3387.jpg
http://i763.photobucket.com/albums/x...n/DSCN3388.jpg

I also started plug welding the rocker panel into place. Anyone else get nervous at this point. Did I forget anything? If I have to take it off now I could destroy it.
http://i763.photobucket.com/albums/x...n/DSCN3389.jpg

I'm a little worried about how the body gets wider on the suburban. Didn't notice it much at first. Now that I'm looking down the body to see if the lines are straight I can see it gets wider from the cowl to the back of the rear doors. Then it stays at that width to the tail lights. The passenger side seems to be like that too so it should be right. Is there anyone with a shiny suburban that can confirm it? Reflections will make it obvious if it's incorrect.

Re: Project Family Hauler
 

The roof line width gets wider on the burb body i am using. I am measuring from the pinch weld seams on the header panels. My pick up back half is 1 5/8" narrower.
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Re: Project Family Hauler
 

That makes sense. I knew they were different when I did floor repairs. It continues to get wider to the back door jambs. The back of the rear doors at weather stripping is 3/4" wider than the back of the front doors. And that is wider than the trucks? I need to measure a truck cab. I'm just trying to figure out how the side will look.
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Re: Project Family Hauler
 

Finally got tired of looking at the large gap at the front of the back door.
These little clamps are the best thing. Can't have too many.
http://i763.photobucket.com/albums/x...n/DSCN3404.jpg

Then lots of welding to get the addition on. I plug welded the skin to the door frame then added the extra 7/8".
http://i763.photobucket.com/albums/x...n/DSCN3409.jpg

After I got the edge fitted so the door gap was close I added another layer of sheet metal to the back. It sandwiches the lip from the door frame and I plug welded it to the door frame also. Then welded the two edges together to make it thicker.
If anyone ever says you have too many clamps show them these pics. I could use a few more.
http://i763.photobucket.com/albums/x...n/DSCN3410.jpg
http://i763.photobucket.com/albums/x...n/DSCN3411.jpg

After much grinding it looked like this. And with the two layers with staggered joints it is very rigid.
http://i763.photobucket.com/albums/x...n/DSCN3412.jpg
http://i763.photobucket.com/albums/x...n/DSCN3415.jpg
http://i763.photobucket.com/albums/x...n/DSCN3420.jpg

Here is the inside layer of metal after I plug welded it.
http://i763.photobucket.com/albums/x...n/DSCN3419.jpg

And after I finished grinding it. Looks clean. Will add seam sealer to edge before painting.
http://i763.photobucket.com/albums/x...n/DSCN3423.jpg

I started the back edge of the door also. It was also just one layer of sheet metal that is plug welded to the door frame. Added a layer inside like the front and got it ground down to set the door gap and ran out of steam for today.
http://i763.photobucket.com/albums/x...n/DSCN3421.jpg

Now I need to finish the back and then do the bottom to get the gap correct.

Re: Project Family Hauler
 

Very nice. You have way more patience than I.

Re: Project Family Hauler
 

Ding!! You just gave me an idea for the front edge of my doors!!! Thanks man!

Re: Project Family Hauler
 

If you have as many donor doors as I have you are in good shape. I cut just in front of the door handle and had to section almost 1/4" to get the body lines to match.
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Re: Project Family Hauler
 

Working on matching the body curve on the door with the curve on the suburban. They are close but not exact. I used the rear part of a drivers door to make the rear of the door but as I keep finding out suburbans are different. Now is the time to make it work. The top part of the door was in too far so I made the body match, the middle of the door was flatter so I cut the suburban skin so I could flatten it.

http://i763.photobucket.com/albums/x...n/DSCN3425.jpg

The bottom of the door lines up with the rocker panel but was rusted out on the suburban all the way to the wheel well. I finally opened up the body cavity (yes I did a body cavity search), looking for rust.

http://i763.photobucket.com/albums/x...n/DSCN3426.jpg

http://i763.photobucket.com/albums/x...n/DSCN3428.jpg

http://i763.photobucket.com/albums/x...n/DSCN3432.jpg

Then the worst thing happened, my welder stopped welding. I know I was almost out of gas, so I checked my wire spool and it was empty. I looked at the time and the welding supply store had been closed for 15 minutes.:banghead:

Done for the weekend!!!





Wrong, if the rain quits I can cut out a patch panel from extra parts. I don't like taking electric tools out in rain storms (reason for new garage).

Re: Project Family Hauler
 

Wow! I have less inner wheel well than you do! That doesn't look too bad!
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Re: Project Family Hauler
 

I was really surprised too. The way the outside looked and I know how much dirt came out of that cavity. It was full of dirt up to the inspection plug in the wheel well (plug was missing).

Re: Project Family Hauler
 

Well anyone from Washington or somewhere close will understand this. It quit raining and was only a drizzle so I ran my extension cord to my pile of parts and cut off a patch panel from an old bedside.

I cut and fit the panel. Suburbans have a spot where the floor is spot welded to the skin and I thought it was good. So I cut there and the splice will be supported by the floor. It goes up high because there was a dent at a bad spot. See the arrow.

http://i763.photobucket.com/albums/x.../DSCN3425c.jpg


http://i763.photobucket.com/albums/x...n/DSCN3433.jpg


http://i763.photobucket.com/albums/x...n/DSCN3434.jpg

Then I finished cleaning the back of the patch and the inner wheel well with POR 15 clean and prep. I will paint it tomorrow. Got nothing else to do.

http://i763.photobucket.com/albums/x...n/DSCN3439.jpg


http://i763.photobucket.com/albums/x...n/DSCN3440.jpg


http://i763.photobucket.com/albums/x...n/DSCN3441.jpg


Here is the saddest site this weekend.
No more wire.
http://i763.photobucket.com/albums/x...n/DSCN3442.jpg

And almost no gas.
http://i763.photobucket.com/albums/x...n/DSCN3443.jpg

Re: Project Family Hauler
 

Lookin really good man! I hear ya on the consumables!
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Re: Project Family Hauler
 

I know how it is. I was trying to get as much work done on my Suburban as possible when it started raining. I did get the mufflers on during the hale storm though. The cops weren't liking the open headers much and it drew a lot of attention.

If you're ever down in Orting, I work at Safeway. Stop by, you'll probably see my Suburban out in the parking lot. I work mornings.

Re: Project Family Hauler
 

You probably have seen my finished 67 Chev. I've had it at the Kingsman show in June for around 10 years.

It rained so much yesterday I had a moat around my garage. Glad I raised it a foot above high tide here in the valley.
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Re: Project Family Hauler
 

The only one I saw this last June was this one. I was probably working during the Kingsman show.

https://sphotos-b.xx.fbcdn.net/hphot..._3223887_n.jpg

Re: Project Family Hauler
 

Very nice work! I was thinking on the front door body line not matching up when using it for a rear door. My solution was to maybe cut up a long bed bed side to try to use as an outer skin. IDK if it'll work or not? Maybe I'll get to my crew cab project this year. It's looking very unlikely though. I have to get the Longhorn drivable first. Haha By the way, I hope you and your family have a Very Merry Christmas!!!!!

Re: Project Family Hauler
 

This is my other truck.
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Re: Project Family Hauler
 

Don't know if that would help. The suburban could still be different after that. I'm just going to blend it back to the wheel opening. I'm basing the body line difference on the door jamb from the truck cab. It matches my new door but slightly different than suburban skin. My cut was less than 3/16" and still have 1/16" gap to weld. That was enough to match bodyline.
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Re: Project Family Hauler
 

After all my welding and grinding I found my new garage needed some airflow. The smoke and dust were landing on everything so I put a fan in the ceiling. It vents out the roof. Now when I recoup from Christmas I will get more gas and wire for my welder and will see how much the fan helps.
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Re: Project Family Hauler
 

I'm back. Been working on the other truck so I had a break.

Replaced all my old braided fuel line, it was 14 years old and my garage smelled like gas all the time. Plumbed it for a return style system. Used teflon lined braided line this time with steel hardline in the frame. Much easier to work with. This should fix my vapor locking problem too.
http://i763.photobucket.com/albums/x...psd165d06d.jpg
http://i763.photobucket.com/albums/x...ps442771fd.jpg

Took some boards out of my bed to access the fuel line.
http://i763.photobucket.com/albums/x...psd620ae98.jpg

Then put the bed wood back together.
http://i763.photobucket.com/albums/x...psc1526d14.jpg

Then I get back to the suburban.
Painted inside before welding patch panel.
http://i763.photobucket.com/albums/x...ps171b2f71.jpg

Patch welded in and smoothed. Also replaced the door skin again.
http://i763.photobucket.com/albums/x...ps932b0cd4.jpg

Did a little massaging of the latch and the door closes with just a click now.
http://i763.photobucket.com/albums/x...ps1961f6f2.jpg

Happier with the door skin now. It fits the curve better, the top is even with the inside and there is no bulge in the middle.
http://i763.photobucket.com/albums/x...ps80ea9854.jpg

Started setting the door gaps.
http://i763.photobucket.com/albums/x...ps509c1cbd.jpg

Bottom door gap is 1/8"
http://i763.photobucket.com/albums/x...ps08e2d510.jpg

Rear door gap still needs some work. But getting closer.
http://i763.photobucket.com/albums/x...ps62d4c0f6.jpg

Re: Project Family Hauler
 

I'm back. Been working on the other truck so I had a break.

Replaced all my old braided fuel line, it was 14 years old and my garage smelled like gas all the time. Plumbed it for a return style system. Used teflon lined braided line this time with steel hardline in the frame. Much easier to work with. This should fix my vapor locking problem too.
http://i763.photobucket.com/albums/x...psd165d06d.jpg
http://i763.photobucket.com/albums/x...ps442771fd.jpg

Took some boards out of my bed to access the fuel line.
http://i763.photobucket.com/albums/x...psd620ae98.jpg

Then put the bed wood back together.
http://i763.photobucket.com/albums/x...psc1526d14.jpg

Then I get back to the suburban.
Painted inside before welding patch panel.
http://i763.photobucket.com/albums/x...ps171b2f71.jpg

Patch welded in and smoothed. Also replaced the door skin again.
http://i763.photobucket.com/albums/x...ps932b0cd4.jpg

Did a little massaging of the latch and the door closes with just a click now.
http://i763.photobucket.com/albums/x...ps1961f6f2.jpg

Happier with the door skin now. It fits the curve better, the top is even with the inside and there is no bulge in the middle.
http://i763.photobucket.com/albums/x...ps80ea9854.jpg

Started setting the door gaps.
http://i763.photobucket.com/albums/x...ps509c1cbd.jpg

Bottom door gap is 1/8"
http://i763.photobucket.com/albums/x...ps08e2d510.jpg

Rear door gap still needs some work. But getting closer.
http://i763.photobucket.com/albums/x...ps62d4c0f6.jpg

Re: Project Family Hauler
 

Wow... I was just wondering how your 4 door was coming! Looking good!

Re: Project Family Hauler
 

Thanks. Let me tell you I'm not going to make a career out of this and won't do it again. Too many curves to get lined up.
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Re: Project Family Hauler
 

Well I made progress this weekend. (well a few other weekends too). Got most of the rough bodywork taken care of and sprayed some primer surfacer on the doors to see how they look.

http://i763.photobucket.com/albums/x...psc35bcbdb.jpg

http://i763.photobucket.com/albums/x...ps7ee5d658.jpg

Re: Project Family Hauler
 

Sure looks straight to me!
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Re: Project Family Hauler
 

Sweet! :metal:

Re: Project Family Hauler
 

Thanks
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Re: Project Family Hauler
 

Thats looking great! keep up the pace and it will be a family hauler sooner than ya know it!

Re: Project Family Hauler
 

I did get it turned around in the garage. Pretty easy when it's on roller skates.
I am making a patch panel list for the rainy season.
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Re: Project Family Hauler
 

Now for the ADD of my life. Going to help my dad on some rust repair on his quirky project. 1961 Corvair Lakewood wagon.
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Re: Project Family Hauler
 

Welcome back!

Re: Project Family Hauler
 

Awesome lakewood!