Re: Project Family Hauler
 

I took almost 2 years off. The hinge problem slowed me down as much as the rain. I ran out of excuses so I started working on it again. Hopefully I can do more this weekend around pumpkin projects.
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Re: Project Family Hauler
 

Well I got some more done this weekend. Finished filling in all the gaps on the hinge side of the door jamb.

http://i763.photobucket.com/albums/x...n/DSCN3350.jpg

http://i763.photobucket.com/albums/x...n/DSCN3351.jpg

Also took the door skin on and off too many times to count.
http://i763.photobucket.com/albums/x...n/DSCN3352.jpg

http://i763.photobucket.com/albums/x...n/DSCN3353.jpg



Then I had to get the door lock linkage hooked up. The rod had to clear the window channel to I made a new one.
http://i763.photobucket.com/albums/x...n/DSCN3362.jpg

http://i763.photobucket.com/albums/x...n/DSCN3358.jpg


And I filled in the rest of the holes on the latch side of the door.
http://i763.photobucket.com/albums/x...n/DSCN3359.jpg

Latches and locks now.

Re: Project Family Hauler
 

Finished grinding the inside of the door and hopefully done welding on the lower inside part also. POR15 the inside of the door. Maybe that means I'm almost ready to close up the work area and the skin will stay on. Maybe.

http://i763.photobucket.com/albums/x...n/DSCN3366.jpg

This is the hinge support from the donor truck. It should stabilize the hinge mounts.

http://i763.photobucket.com/albums/x...n/DSCN3367.jpg

Looks better to hide the rusty colors.

Re: Project Family Hauler
 

Finished up rewelding the window frame in what I HOPE is the final position.

http://i763.photobucket.com/albums/x...n/DSCN3373.jpg

http://i763.photobucket.com/albums/x...n/DSCN3372.jpg

Then I worked over the door skin so it fits the frame good. The gap for the window is 1" on all my other doors so that was the number I had to get when the skin fit right. I'm there. Also with all my cutting the drain holes at the bottom of the door disappeared so I made new ones.

http://i763.photobucket.com/albums/x...n/DSCN3374.jpg

Then I started to finish the rocker panels. I started with a drivers side rocker for the rear door. Not much fit right. They aren't cut for a B pillar and the curve is wrong. Then I had to join it to the front rocker to make it flow. Cut, cut, cut. Weld weld weld. It is now one rocker that runs like a uni-brow. When its done I will plug weld it to look like its stamped.

http://i763.photobucket.com/albums/x...n/DSCN3370.jpg
http://i763.photobucket.com/albums/x...n/DSCN3371.jpg

Re: Project Family Hauler
 

Nice to see you back at it. Keep it up.

Re: Project Family Hauler
 

Glad to be back at it. Hope no one gave up on me.
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Re: Project Family Hauler
 

Great work! It's really coming together now!

Re: Project Family Hauler
 

Think I got the rocker panels mostly done this weekend.
One giant one now.
http://i763.photobucket.com/albums/x...n/DSCN3375.jpg

Lots of grinding to get this part to look good. Also found all the curves in the rocker panels. They curve in at the front AND back. Had to cut and massage the part that connects them. It was in almost 1/4" from where the rockers are. I think I need to go to massage school for metal. I'm really slow at all this.
http://i763.photobucket.com/albums/x...n/DSCN3376.jpg
http://i763.photobucket.com/albums/x...n/DSCN3377.jpg
http://i763.photobucket.com/albums/x...n/DSCN3378.jpg
http://i763.photobucket.com/albums/x...n/DSCN3379.jpg

After I got it fit and ground down I remembered since the rear door is suicide I need to have the rubber bumper up front. So I matched the one for the front door.
http://i763.photobucket.com/albums/x...n/DSCN3380.jpg

http://i763.photobucket.com/albums/x...n/DSCN3381.jpg

Now that the door is fitting good I can maybe move forward again.

Re: Project Family Hauler
 

Lookin good man! I'm jealous!
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Re: Project Family Hauler
 

Nothing to be jealous about yet. I'm still moving at a snails pace. With the cold wet weather up here I'm glad to have my new garage, but I think I need an exhaust fan to clean all the welding and grinding smoke and dust.
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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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