Bringing the '65 back to life

[racecougar]

I just had to go by the shop tonight to put the door back on the truck and get a look at it. Dad approves.

[racecougar]

Well, after a long, but unfruitful, search for a passenger side door in good condition, we've decided to repair the original. It has a heck of a dish toward the rear lower section that was full of filler.


It'll need plenty of rust repair as well.

[bj383ss]

Originally Posted by racecougar

Well, after a long, but unfruitful, search for a passenger side door in good condition, we've decided to repair the original. It has a heck of a dish toward the rear lower section that was full of filler.


It'll need plenty of rust repair as well.

Not the best but looks better than both my doors.

[Ta2Don]

Still advancing

[racecougar]

Stuck the door on the truck this morning to scope out the fitment and start bumping the outer skin back into shape.


Then it was time to get after the rust. Partial patch panels are available for these doors, but like all the other patch panels, they're not perfect. The most glaring difference in these is the lack of radius at the corners of the lower character line (circled). Luckily we can skirt that area in this instance.


The patch panel tagged into place. It'll be fully burned in later on. This thin old sheetmetal would be MUCH easier to weld with gas, but I'm still getting by with .035 flux core. Patience is key.

[racecougar]

The front corner is complete. I'll attack the rear corner next weekend.

[Modges'66]

Really nice work!
I like!!!

[Ta2Don]

Very Nice!

[racecougar]

Thanks guys!

Replaced the rear corner (inside and out), then welded up the extraneous mirror holes, and stuck the door back on the cab today.

[Ta2Don]

Zippin' along...

[Grizz1963]

Looking good there mate.

[racecougar]

Thanks!

We massaged the door skin a bit today while it was mounted to the cab, then located and drilled the three holes for the side-view mirror. After that, it was back to the table for a few touch up welds and a whole lot of sanding. Of course just when I thought I was done welding, I found four more holes from yet another mirror installation. A few minutes with the welder and a Roloc and they disappeared.

[racecougar]

Apparently the forces of nature do not want me to work on the '65 this weekend. I had to go the long way around to the shop yesterday morning after a fallen tree closed the road just a mile from the shop. Then of course when I arrived, the power went out. I tried again today, but after just a couple of minutes of work, the air compressor pump locked up. Maybe next weekend.

[racecougar]

Dad retrofitted the new compressor pump and we fired it up this afternoon. It's good to be back in business. It might not seem like much has happened, but the tedious job of stripping the door down to bare steel is just about complete.

I plan to take the day off tomorrow to take the Coug on a little cruise with the wife and some friends, then get back to this door Sunday afternoon.

[Ta2Don]

Glad to hear the compressor issue is resolved...

Cruise, then truck time...

[racecougar]

Had a pretty awesome day cruising back roads down to Ste. Gen for some beers yesterday. The wife and I took the Coug and the best man from my wedding and his wife rode their Harley. The route we picked was excellent.


Brought the father in law over to see the shop, the truck, and our land today, then I got back to work on this door. It's getting there.

[racecougar]

Finished sanding the inside of the passenger door this morning, then laid down the first coat of primer.

[racecougar]

Arms...tired...no more sanding...

[racecougar]

Dad blocked out the driverside door today, while I kept working away at the passenger side door, jam, and cab corner.

[racecougar]

Another day spent working with filler on the passenger side door, jam, and cab corner. It's coming along, but it'll probably need about one more day of blocking/filling before it's ready for primer.

[Ta2Don]

Very Nice!!!

[racecougar]

Thanks, Don!

See the note taped in the window opening for my sentiments regarding the door, jam, and cab corner. It's ready for primer.

[Ta2Don]

Nice... My FIL used to say, when building his garage, "We ain't building no piano."

[racecougar]

Exactly.

Swung by the shop tonight and threw a coat of primer on the door, jam, cab corner, and rocker.

[racecougar]

Today, I remasked the cab, then blocked it all out...


...while Dad blocked out the door. We have a little more work to do before the next coat of primer, but we might get to it tomorrow.