66 GMC long story longer...

[jweb]

There is a local guy that has tons of parts. It won't be cheap if you want a perfect door but I'm sure he has it. Chris is just up in Woodburn.

https://portland.craigslist.org/clc/...104179763.html

[rustyrodknocker]

I was going give him a call. I have tried him in the past but he has not called back.

[rustyrodknocker]

Can't complain about the drive home. With so many people working from home I have time that I forgot existed. Tonight was the first night I have done project stuff after work in many years.
Not much but it helps keep some continuity during the week.

[rustyrodknocker]

Bit the bullet today and started to repair my lousy doors.

[rustyrodknocker]

Completed the structural repairs to the drivers door today. I had hoped to finish the day with the inside of the door stripped and epoxy primed. Didn't get so far. If the commute continues to be good this week I may get it stripped, glass removed and ready for primer in a couple evenings.

[rustyrodknocker]

I figured the rustoleum would be a good seal sealer. The factory stuff was gone or cracked so I wired wheeled around the door. I'll give it another coat tomorrow.

[rustyrodknocker]

Moving on to the outside of the door. A couple of patch panels and some dents to pull. A little more massaging to do then its time for some primer and on to the next thing.

[rustyrodknocker]

More sideways photos....

Not sideways!

[rsavage]

Following your progress.

[Southcity]

Keep up the great work! I'll have to do this to mine in the near future and your thread is a great reference.

[rustyrodknocker]

Thanks guys, today I tried a different method on the patches. It works pretty nice for panels that you can't use butt joint clamps on due to access restrictions.
You pre form you panel and fit it up with around an inch over lap. Tack it up then relief cut a corner. Push it down flush and tack. It leaves you with a skeleton that you have to fish out from behind.
That can be a pain and I still have one stuck.

This is a method I seen on youtube by a guy name Fitzy in Newfoundland.

[clemsonteg]

Originally Posted by rustyrodknocker

Thanks guys, today I tried a different method on the patches. It works pretty nice for panels that you can't use butt joint clamps on due to access restrictions.
You pre form you panel and fit it up with around an inch over lap. Tack it up then relief cut a corner. Push it down flush and tack. It leaves you with a skeleton that you have to fish out from behind.
That can be a pain and I still have one stuck.

This is a method I seen on youtube by a guy name Fitzy in Newfoundland.

Could you share the video link?

[rustyrodknocker]

Originally Posted by clemsonteg

Could you share the video link?

I can't seem to override my app and open in a web browser. But this is the guy and the first video. I watched him explain the technique in several videos. I was not sold on this first one, as I had tried a version of it many years ago and was not happy with it. However you can't argue the man's results. It is fast and accurate. But I do have a piece stuck in the door that I think will live there for ever. I think you need to do light tacks to keep from fusing the cut out skeleton and when tacked in get the piece out.

Another thing I had never seen is cutting in on a 45 to create a tighter gap when fit. I think this would add a great deal of time savings also. I did one door patch that way. It came out good. I have always preferred a full 1/16" gap on a blind panel.
This lessens the chance of warping. When heat shrinkage occurs the two sides of the joint can collide and buckle if gap was insufficient.

Panels that can be planished can be fit tight and gas or tig welded. In just a moment you can stretch it back into shape. Very quickly if done while still hot. Using this method requires no grinding. Welding the joint takes longer but time and mess are reduced from no grinding.

[clemsonteg]

Thanks for sharing. He’s really great! I think this video shows the techniques you mentioned https://youtu.be/9MPykdZF9YU

[rustyrodknocker]

Not much to report, other than some parts in sealer today. May go for the new rocker install tomorrow. Then may jump into some motor work next week. Need to get it running good so its easier to move around.

[Southcity]

You're making great progress in a short period of time, well done! we all appreciate your updates and pics.

[rustyrodknocker]

Well today was about 3 steps forward and 13 steps back. The good news is the fit up of the door and rocker are getting into the ball park. The other news is...

[rustyrodknocker]

It seems that everything is an approximation with these old trucks. The doors are approximately the same shape as the door opening. However, when I tried to fit the door today I was not even in the realm of approximate.

The floor was a half inch high at the front of the jam. I don't know how the hell I did that. I laid the new floor on the brace and plug welded it. The brace must have been pulled up and out of shape from me yarding the old floor out.

There was no easy way to back up. So many pieces tie together right there. After two hours off contemplating I just laid into it and sawzalled through the upright and about a foot of floor.

Then I stood on the brace and jumped up and down. It came down about 5/16". I tried fitting the door and rocker but it needed more. So I wedged it a 1/2" and Im getting close.

Too many optical delusions. I tried to square the rocker and eyeball it against a straight edge a dozen times. And I thought it was close. I had checked the rocker against the rear of the jam for square knowing that the back and bottom of the door form a right angle. It was a mile out and I dismissed it to tolerance thinking that the rocker could not be out a half inch.

Well it was. I could have easily measured the passenger side. But I assumed the floor brace was where it lived. Lesson learned...

[rustyrodknocker]

I do think the rocker is a little long and will probably take some length off the front.
I have it butted all the way back against the rear quarter. But the fender backs into it before the door gap gets to where I would like it to be.

[rustyrodknocker]

The continuing continues. Still have not completed rocker. Need to push through.

Starting exploring some color concepts.